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INTRODUCTION GENERAL This section has the description and the repair procedures for the electric brake assembly.

DESCRIPTION AND OPERATION Electric Brake (See FIGURE 1.)

The electric brake is installed on the top of the drive motor. The brake assembly has an electric magnet, a friction disc, a hub, and two brake plates. The electric magnet is fastened to the housing of the drive motor.

The hub is installed on the shaft of the drive motor. The friction disc is installed between the brake plates, which are mounted on the magnet assembly. The friction disc engages the hub and rotates with the shaft of the motor.

2

1

3

When the operator does not use the brake switch, the brake is automatically applied. When the brake is applied, springs push the armature plate against the friction disc and push the friction disc against the back plate. The operator must push the brake switch to release the brake. The brake switch energizes the electric magnet. The magnet pulls the armature plate away from the friction disc.

Several conditions can cause application of the brake because the brake is used on several different units.

These are the conditions that apply the brake: Brake switch is released.

Key switch is turned to OFF. Power disconnect circuit is activated.

A side rail on the operator’s compartment is raised.

The automatic shut–off circuit is activated.

A lift chain loosens and activates an interrupt

4 4

switch.

Brake Switch (See FIGURE 4.)

The brake switch assembly is in the floor of the operator’s platform. The assembly can have one switch or two switches. When two switches are installed, the mechanism operates both at the same time.

1.

2.

3.

4.

BACK PLATE FRICTION DISC HUB HOLES WITH THREADS

FIGURE 1. ELECTRIC BRAKE (TYPICAL)

NOTE: If the lift truck must be moved without battery power, the brake can be manually released. There are three holes with 1/4–20 UNC threads in the back plate.

Install capscrews in the holes. Use the capscrews to push the armature plate away from the friction disc.

WARNING When the brake is manually released, put a “DO NOT OPERATE” tag on the steering wheel.

1

REPAIRS ELECTRIC BRAKE

1. Disconnect the wires for the electric magnet.

Removal and Disassembly

2. Remove the six capscrews that fasten the brake assembly to the motor.

R25A, R30C, R30CA, R30CH, R30DH, N30–50CA, N30–40CR (See FIGURE 2.)

3. If the friction disc and the hub are connected by springs, remove the springs.

WARNING Disconnect the battery connector before you begin repairs.

NOTE: Replacement of the friction disc does not require removal of the brake. Use the necessary procedures in steps 3. and 5. to remove the friction disc. After a friction disc is installed, make sure the adjustment in step 3., Assembly and Installation, is correct.

4. Remove the brake assembly from the motor. If necessary, remove the hub from the shaft of the motor.

Keep the key for installation with the hub.

5. Disassemble the brake by removing the three adjustment nuts on the back plate. Remove the back plate, the three springs, and the friction disc. Remove the capscrews that fasten the armature plate to the magnet assembly. Keep the set of washers with each capscrew.

Remove the armature plate and the springs.

R30E, R30EA (See FIGURE 3.)

2

1

6

5

7 4

WARNING Disconnect the battery connector before you begin repairs.

0.28 to 0.33 mm (0.011 to 0.013 in)

3

24 VOLT UNIT – 17.5 mm (0.69 in) 36 VOLT UNIT – 34.0 mm (1.34 in)

1. Open the motor compartment. Check for alignment of the four holes in the friction disc with the four capscrews in the magnet assembly. Slowly operate the traction motor to align the holes and the capscrews.

Disconnect the battery connector.

8

11436

1.

2.

3.

4.

BACK PLATE ARMATURE PLATE SPRING (6) SPRING (3)

5. FRICTION DISC 6. HUB 7. ADJUSTMENT NUT (3) 8. WASHERS

FIGURE 2. ELECTRIC BRAKE

2

NOTE: Replacement of the friction disc does not require removal of the brake. Use the necessary procedures in step 5. to remove the friction disc. After a friction disc is installed, make sure the adjustment in step 4., Assembly and Installation, is correct.

2. Disconnect the wires for the magnet at the connector in the wire harness.

3. Remove the four capscrews that fasten the brake assembly to the motor. The capscrews are installed with adhesive sealant.

4. Remove the brake assembly from the motor. If necessary, remove the hub from the shaft of the motor.

Keep the key for installation with the hub.

3 1

4 2

5

7

6

capscrews to 6 N.m (5 lbf ft). If springs were removed from the hub and the friction disc, install the springs.

7

5. Connect the wires for the electric magnet.

R30E, R30EA (See FIGURE 3.)

1. Install the twelve springs in the magnet assembly.

12350

0.33 to 0.38 mm (0.013 to 0.015 in) 1.

2.

3.

4.

5.

ARMATURE PLATE RETURN SPRING (3) CAPSCREW (3) SPRING WASHER (3) BACK PLATE

10

9

8 HUB FRICTION DISC SPRING (12) MAGNET ASSEMBLY 10. BORE, CAPSCREW 6.

7.

8.

9.

FIGURE 3. ELECTRIC BRAKE, R30E AND R30EA

5. Disassemble the brake by removing the three socket–head capscrews and spring washers. Then remove the back plate, return springs, friction disc, armature plate, and twelve brake springs.

Assembly and Installation R25A, R30C, R30CA, R30CH, R30DH, N30–50CA, N30–40CR (See FIGURE 2.)

1. If the hub was removed, install the key and the hub.

Install the washer and the nut. Tighten the nut to 108 N.m (80 lbf ft). Loosen the nut to the first alignment position for the cotter pin. Install the cotter pin.

2. Install the three capscrews and spring washers in the back plate. Put the return springs on the capscrews. Put the friction disc against the back plate and install the armature plate on the capscrews.

3. Install the plate assembly on the magnet assembly.

Carefully turn the capscrews to engage the threads.

4. Evenly tighten the capscrews until the clearance between the electric magnet and the armature plate is 0.33 to 0.38 mm (0.013 to 0.015 in). See FIGURE 3.

5. Install the brake assembly on the motor. Use an adhesive sealant on the capscrews and tighten the capscrews to 12 N.m (9 lbf ft).

NOTE: Acceptable adhesive sealants include those below: LoctiteR Corporation Fel–Pro Inc. Saf–T–Lok Chemical Corp.

No. 290 Pro–Lock Saf–T–Lok S90

6. If the hub was removed, install the key and the hub.

Install the washer and nut. Tighten the nut to 108 N.m (80 lbf ft). Loosen the nut to the first alignment position for the cotter pin and install the cotter pin.

7. Connect the wires for the electric magnet.

2. Install the six springs and the armature plate on the magnet assembly. Install each capscrew with a set of washers. There are 13 washers for each capscrew on 24 volt units. There are 29 washers for each capscrew on 36 volt units. Tighten the capscrews to get the dimension shown in FIGURE 2.

BRAKE SWITCH (See FIGURE 4.)

3. Install the springs for the back plate. Install the friction disc, the back plate, and the adjustment nuts.

Evenly tighten the nuts until the clearance between the electric magnet and the armature plate is 0.28 to 0.33 mm (0.011 to 0.013 in). See FIGURE 2.

The brake switch assembly is in the floor of the operator’s platform. Remove the cover of the assembly to get access to the switch. Put labels on the wires. Make sure the labels accurately describe the connections on the switch. Disconnect the wires and remove the switch, or the switches, as necessary. When a switch is installed, connect the wires according to the labels. Figure 4 shows typical connections. If necessary, see the section DIAGRAMS for your model.

4. Align the friction disc with the hub and install the brake assembly on the motor. Install the six capscrews that fasten the brake assembly to the motor. Tighten the

WARNING Disconnect the battery connector before you begin repairs.

3

2

4 5

3

4

2 1 SINGLE SWITCH ARRANGEMENT*

5 1

4

1

DOUBLE SWITCH ARRANGEMENT*

1.

2.

3.

4.

5.

SCREW, SWITCH MOUNT PLUNGER COVER HOUSING SWITCH

3920

*See the section DIAGRAMS for the codes of the wires on a specific model.

FIGURE 4. BRAKE SWITCH

TROUBLESHOOTING PROBLEM The brake will not release.

POSSIBLE CAUSE The battery is discharged.

The battery is not connected.

The wires to the brake assembly are not connected.

The wires to the brake switch are not connected.

The brake switch is damaged.

The brake assembly is not adjusted correctly.

The automatic shut–off circuit has applied the brake.

The brake will not stop the lift truck.

The brake is not adjusted correctly.

The friction disc is worn or damaged.

There is oil or grease on the friction disc or brake plates.

4

BATTERY SPECIFICATIONS MODEL

VOLTS

R30E/EA/EF

24V

R30E/EA/EF

36V

R30ES

24V

BATTERY SIZE* MIN/MAX

MINIMUM COMPARTMENT SIZE LENGTH X WIDTH

LENGTH

WIDTH

368 x 975 mm 14.50 x 38.38 in.

889/972 mm 35.00/38.25 in.

330/362 mm 13.00/14.25 in.

343 x 914 mm 13.50 x 36.00 in.

786/911 mm 30.94/35.88 in.

337 mm 13.25 in.

WEIGHT MIN

MAX

681 kg 1500 lb

817 kg 1800 lb

817 kg 1089 kg 1800 lb 2400 lb 466 kg 1025 lb

550 kg 1210 lb

Compartment width is across width of lift truck. Battery length installed across lift truck, battery width installed front– to–back. *Maximum height for R30E/EA/EF batteries is 787 mm (31.0 in). Maximum height for R30ES batteries is 591 mm (23.25 in).

TRANSISTOR CONTROLLER ADJUSTMENT POINTS PLUG CURRENT ADJUST (CW = higher plugging current)

CURRENT LIMIT ADJUST (CW = higher current limit)

ACCELERATOR RAMP ADJUST (CW = faster acceleration)

NOTE: REFER TO THE SECTION CURTIS TRANSISTOR MOTOR CONTROLLER, 2200 SRM 411 FOR THE CORRECT ADJUSTMENTS. USE A SMALL INSULATED SCREWDRIVER TO MAKE ADJUSTMENTS. DO NOT TIGHTEN SOCKET HEAD PLUG SCREWS TOO TIGHT. THREADS ARE EASILY DAMAGED.

EV–100 TRACTION CARD SETTINGS

MASTER DRIVE UNIT ITEM

5485

Drive Tire Size R30E/EA/EF R30ES Torque Values Capacity R30E/EA/EF R30ES

UNIT VOLTS 24V

7.5

1.5

9

N/A

5

36V

7.0

2.0

9

N/A

5

NOTE: See the section EV–100 REPAIRS AND ADJUSTMENTS, 2200 SRM 288 for correct adjustment procedures.

Lubricant

SPECIFICATION 13.5 X 5.5 X 8 12 x 5.5 x 8 See Torque Specifications Table 3.8 Litre (1 Gal) 2.5 litre (2.64 U.S. Qts.) See the section PERIODIC MAINTENANCE, (8000 SRM 410)

1

SYSTEM II ELECTRONIC CONTROL MODULE (ELECTRIC POWER STEERING) COMPONENT FUNCTIONS COMPONENT R2 R3 R4

LIGHT EMITTING DIODES DISPLAY

FUNCTION SLOW TRAVEL SPEED MDU CENTERING STEERING INPUT BALANCE

S1–1 S1–2 S1–3 S1–4

LIFT HEIGHT MODE NOT USED NOT USED NOT USED

TP3 TP4 TP5 TP6 TP7 TP8

5 VOLTS SUPPLY 14 VOLTS SUPPLY STEERING INPUT SIGNAL MDU COARSE MDU FINE BATTERY NEGATIVE (COMMON)

12360

TRANSISTOR RESISTANCE TERMINAL CONNECTIONS

1 2

RESISTANCE VALUES IN OHMS

+

–

B11 B11 C1 C1 C2/E1 C2/E1

C2/E1 C1 B11 C2/E1 C1 B11

80 to 400 450 to 600 OPEN OPEN 350 to 550 80 to 400

B22 B22 C2/E1 C2/E1 E2 E2

E2 C2/E1 B22 E2 C2/E1 B22

80 to 400 450 to 600 OPEN OPEN 350 to 550 80 to 400

LED

LED ON

12370

NORMAL DISPLAY 1 2 3 4 5 6

STEERING LEVER CENTERED STEERING LEVER CLOCKWISE STEERING LEVER COUNTERCLOCKWISE A A HIGH LIFT TRACTION SHUT–OFF FAULT TRACTION SHUT–OFF CONDITION MDU TURNED IN WRONG DIRECTION MDU DID NOT TURN MDU SIGNAL OUT OF RANGE STEERING SIGNAL OUT OF RANGE MDU AND STEERING SIGNALS OUT OF RANGE CHECKSUM ERROR WATCHDOG RESET NO POWER TO ECM

Plug pin socket 4 (M1), pin socket 7 (M2) Plug pin socket 6 (M1), pin socket 9 (M2)

2

CONDITION

LED OFF

A A A A A A A A A A A A A A A A A A

A LED ALTERNATING

TERMINAL AND PIN ARRANGEMENTS FOR THE EV–100 CONTROL CARD * See the section DIAGRAMS, 8000 SRM 424 for wire #.

BRN GRN YEL GRY BLK 6

oo o 1 2 3

8

1 2 3

A B 4 5 6 4 5 6 oo o oo o

o o o o o o o 1

oo o TB1 TB4

TB2

2

3

4

5

6

7

C 8 9 10 11 12 13 14 o o o o o o o

TB3 TB5

TB6

BLU

RED

W/BLU 6

WHT

ORN PUR W/PUR

8 W/RED

NO.

PLUG A*

PLUG B*

TERMINALS

PLUG C

(PAX)

(PBX)

(TBX)

(PCX)

FUNCTION

PA1 PA2 PA3 PA4 PA5 PA6

Not used on most trucks. Also signal from wire guidance ECM (wire 106).* Not used.

Not used.

Not used.

Not used.

Not used.

PB1 PB2 PB3 PB4 PB5 PB6

Not used.

Not used.

Not used.

This terminal has different functions and wire numbers on different trucks.* This terminal has different functions and wire numbers on different trucks.* This terminal has different functions and wire numbers on different trucks.*

TB1 TB2 TB3 TB4 TB5 TB6

5 volt supply to accelerator potentiometer (wire 29 & 29A).

This terminal has different functions on different trucks.

This terminal has different functions on different trucks.

Battery voltage supply from key switch (wire 10).

Voltage input from FORWARD direction switch (wire 6).

Voltage input from REVERSE direction switch (wire 8).

PC1 PC2 PC3 PC4 PC5 PC6 PC7 PC8 PC9 PC10 PC11 PC12 PC13 PC14

Signal wire from SCR 1 thermal protector (black wire).

Battery negative (brown wire).

Signal wire from current sensor (traction circuit) (yellow wire).

Signal wire from current sensor (traction circuit) (green wire).

Signal wire from SCR 1 thermal protector (gray wire).

Not used.

Battery positive voltage (white wire).

Signal wire to SCR 1 gate (blue/white wire).

Signal from SCR 1 cathode (blue wire).

Signal wire to SCR 2 gate (white/red wire).

Connection between filter for SCR 2 and control card (red wire).

Signal wire to SCR 5 gate ( white/violet wire).

Connection between filter for SCR 5 and control card (violet wire).

Sensor wire for voltage check across capacitor C1 (orange wire).

VOLTAGE

5.0 to 0.0

Battery Voltage Battery Voltage Battery Voltage

3

PLUG PINS P3 – P8

P1 P2

TRANSISTOR MOTOR CONTROLLER

TERMINAL AND PIN ARRANGEMENTS FOR THE CURTIS 1204X – 4406 TERMINAL B+

FUNCTION Connects Plug Diode (Cathode) To Traction Motor Armature Battery (Fuse)

4

B–

Battery Negative To MOSFET Transistors (Emergency Disconnect)

M1

Positive Side Of MOSFET Transistors To Traction Motor Field

A2

Connects Plug Diode (Anode) To Traction Motor Armature

P1

Negative Side Of Accelerator Potentiometer Input

P2

Positive Side of Accelerator Potentiometer Input

P3

Key Switch Input

P4

Forward/Reverse Contactor Output

P5

Interlock (Foot Brake) Input (SRO)

P6

Not Used

P7

Forward Input

P8

Reverse Input

SYSTEM II ELECTRONIC CONTROL MODULE (WIRE GUIDANCE) ECM COMPONENT FUNCTIONS FUNCTION

COMPONENT RT1 RT2 RT4 RT5 RT6 RT7 S1 S2 TP1 TP2 TP3 TP4 TP5 TP6 TP7 TP8 TP9 TP10 TP11 TP12 TP13 TP14 TP15

STEERING POTENTIOMETER MDU POTENTIOMETER STEER SENSOR LOAD SENSOR “MEDIUM SPEED” POT. “SLOW SPEED” POT. TEST SWITCH NOT USED 5 VOLTS SUPPLY 14 VOLTS SUPPLY AUTO/MANUAL INPUT STEERING INPUT SIGNAL MDU COARSE MDU MEDIUM MDU FINE 12:9 SENSOR (LOAD WHEEL) 12:3 SENSOR (LOAD WHEEL) 6:9 SENSOR (STEER WHEEL) 6:3 SENSOR (STEER WHEEL) MOTOR CURRENT NOT USED NOT USED BATTERY NEGATIVE (COMMON)

DISPLAY CODE DESCRIPTIONS DISPLAY 5d 01 5d 02

SLOW DOWN CONDITIONS SLOW TO “MEDIUM SPEED” SLOW TO “SLOW SPEED”

DISPLAY A5 A5 A5 A5 A5 A5 A5 A5 A5 A5 A5 A5 A5 dd

00 01 02 03 04 05 06 10 11 12 13 30 31 dd

DISPLAY dd dd dd dd

05 06 07 40

STOP CONDITIONS LIFT HEIGHT OVER MAXIMUM MDU OUT OF NORMAL RANGE MDU NOT MOVING MDU MOVING WRONG STEER POT OUT OF RANGE GUIDANCE SW FAULT IN AUTO BOTH FOR. & REV. IN AUTO LOW SENSOR SIGNAL LIFT TRUCK OFF GUIDE WIRE HIGH SENSOR RATIO LOW AVERAGE SENSOR LEVEL EPROM CHECKSUM ERROR EEPROM CHECKSUM ERROR TEST MODE SELECTED NON–TRACTION CONDITIONS GUIDANCE SW FAULT IN MANUAL F. & R. SELECTED AT SAME TIME LOGIC BOARD NOT TESTED WATCHDOG RESET OCCURED

NOTE: LEDs 1 AND 2 FLASH FOR ALL OF THE ABOVE CONDITIONS.

TRANSISTOR RESISTANCE TERMINAL CONNECTIONS

RESISTANCE VALUES IN OHMS

+

–

B11 B11 C1 C1 C2/E1 C2/E1

C2/E1 C1 B11 C2/E1 C1 B11

80 – 400 450 – 600 OPEN OPEN 350 – 550 80 – 400

B22 B22 C2/E1 C2/E1 E2 E2

E2 C2/E1 B22 E2 C2/E1 B22

80 – 400 450 – 600 OPEN OPEN 350 – 550 80 – 400

12370

1 2

Plug pin socket 4 (M1), pin socket 7 (M2) Plug pin socket 6 (M1), pin socket 9 (M2)

5

SYSTEM II WIRE GUIDANCE SPECIFICATIONS REQUIREMENTS AT INSTALLATION WIRE DRIVER OUTPUT REQUIREMENTS Standard Frequency Current Optional Frequency Current STRAIGHTNESS OF GUIDE WIRE REQUIREMENTS Maximum Deviation From Straight Maximum Deviation Change Maximum Deviation Between Any Two Points Maximum Deviations Per 3.05 m (10 ft) FLOOR FLATNESS REQUIREMENTS Alternate Flatness Requirements: In Direction Of Vehicle Travel*; Maximum Elevation Difference Maximum Elevation Change Rate At 90° To Direction Of Travel*; Maximum Elevation Difference Maximum Elevation Change Rate In Any Other Direction*; Maximum Elevation Difference Maximum Elevation Change Rate FLOOR MAGNETIC CONDITION REQUIREMENTS Floor Topping

Wire Mesh or Rebar

SPECIFICATIONS

6240 to 6260 Hertz 76 to 80 ma 5192 to 5208 Hertz 34 to 36 ma 3.0 mm per 3.05 m (0.12 in per 10 ft) 1.6 mm per 1.53 m (0.062 in per 5 ft) 0.32 mm per 305 mm (0.0125 in per ft) one deviation Face F35 4.3 mm per 1829 mm (0.17 in per 72 in)* 3.6 mm per 305 mm (0.14 in per ft)* 3.6 mm per 1372 mm (0.14 in per 54 in)* 3.6 mm per 305 mm (0.14 in per ft)* 1.8 mm per 305 mm (0.07 in per ft)* 1.8 mm per 305 mm (0.07 in per ft)*

All iron or steel floor topping must be evenly distributed within 610 mm (24 in) on both sides of the guidewire.

Wire mesh and rebar must be at least 102 mm (4 in) below the guidewire.

Other Magnetic Materials (Pipe, Rails, Drains)

Material must be at least 152 mm (6 in) below or 610 mm (24 in) to the side of the guidewire.

Other Guidewires With Same or Different Frequencies

Must be at least 762 mm (30 in) away from the guidewire in the guide path.

TRUCK SYSTEM REQUIREMENTS LIFT TRUCK SPEED WITH GUIDE PATH DEVIATION Zero Deviation (Load End First Only) 32 mm (1.25 in) Deviation 38 mm (1.50 in) Deviation (R30E Only) 44 mm (1.75 in) Deviation

SPECIFICATIONS 8.8 km/h (5.5 mph) (R30EA only) 6 km/h (4 mph) maximum (R30E) 3.6 km/h (2.25 mph) maximum (R30EA) 3.6 km/h (2.25 mph) maximum Traction Shut–Off

* Segment specification for ALL points within the segment. Segment specifications apply to ALL areas of the guide path (path of truck travel during guided operation).

6

HYDRAULIC SYSTEM ITEM

SPECIFICATION

RELIEF SETTING*

R30E, R30EA, R30EF 17.2 MPa (2500 psi)

HYDRAULIC PUMP Capacity

R30E, R30EA, R30EF 23 litre/min (6.1 gpm) @ 2000 RPM 21 MPa (3046 psi) 50 to 3500 RPM

Maximum Pressure Speed OIL CAPACITY Tank (Full Mark, Approximate) Working Volume System Capacity

R30E, R30EA 32 litre (8.5 gal) 30 litre (7.9 gal) 34 litre (9 gal)

R30ES 22.4 MPa (3200 psi) R30ES 13.06 litre/min (3.45 gpm) @ 2500 RPM 25.2 MPa (3600 psi) 50 to 5000 RPM

R30EF 36 litre (9.5 gal) 34 litre (7.9 gal) 38 litre (10 gal)

R30ES 13.25 litre (3.5 gal) 14.65 litre (3.87gal)

*Oil temperature at 54 to 66° C (130 to 150° F)

TORQUE SPECIFICATIONS ITEM MASTER DRIVE UNIT M12 Axle Capscrew Special Nut At Large Gear Motor Armature Nut 8 mm Case Capscrews, Hex. Nuts & Socket Hd. Capscrews 10 mm Case Capscrews Cover Capscrews Capscrews To Mount Adapter Ring Wheel Nuts STEERING SYSTEM Gear Motor Mount Capscrews & Nuts BRAKE SYSTEM Assembly Mount Capscrews Hub Nut HYDRAULIC SYSTEM Cartridge Valves Flow Regulator Relief Valve, Solenoid Valves, and Manual Lowering Valve Check Valve Coil Nut Nut, Control Valve Mount Capscrew, Hydraulic Pump Mount Capscrew, Hydraulic Pump Housing

SPECIFICATION 110 N.m (81 lbf ft) 60 N.m (44 lbf ft) 54 N.m (40 lbf ft) 23 N.m (17 lbf ft) 46 N.m (34 lbf ft) 9.5 N.m (7 lbf ft) 34 N.m (25 lbf ft) Initial 68 N.m (50 lbf ft) Final 68 N.m (50 lbf ft) Initial 136 N.m (100 lbf ft) Final 31 N.m (23 lbf ft) 12 N.m (9 lbf ft) 108 N.m (80 lbf ft) R30E, R30EA, R30EF

R30ES

20.3 to 24.4 N.m (15 to 18 lbf ft) 47.5 to 54.2 N.m (35 to 40 lbf ft) 115 to 122 N.m (85 to 90 lbf ft) 2.3 to 2.8 N.m (20 to 25 lbf in) 11 N.m (8 lbf ft) 20 N.m (15 lbf ft) 46 N.m (34 lbf ft)

16.3 to 20.3 N.m (12 to 15 lbf ft) 16.3 to 20.3 N.m (12 to 15 lbf ft) 5.4 to 6.8 N.m (4 to 5 lbf in) 16.3 to 20.3 N.m (12 to 15 lbf ft) 20.3 to 20.4 N.m (15 to 18 lbf ft) 10.8 to 13.6 N.m (15 to 18 lbf ft)

WIRE GUIDANCE Sensor Mount Capscrews & Nuts

2.0 to 2.5 N.m (18 to 22 lbf ft)

MAST Mount Capscrews

380 N.m (280 lbf ft)

7

GENERAL INFORMATION

CAPACITIES AND SPECIFICATIONS

ORDERMASTER R30E, R30EA, R30EF, R30ES

PART NO. 897357

8000 SRM 423

8

8000 SRM 423

7/92 (5/92) (11/88) Litho in U.S.A.

DC MOTOR MAINTENANCE ALL ELECTRIC LIFT TRUCKS

PART NO. 897076

620 SRM 294

DC Motor Maintenance

Table of Contents

TABLE OF CONTENTS General ...............................................................................................................................................................

Brush and Commutator Inspection ..................................................................................................................

Hydraulic Pump Motor and Traction Motor.................................................................................................

Steering Pump Motor ....................................................................................................................................

Normal Commutator Surface........................................................................................................................

Commutator Problems ..................................................................................................................................

Brush Replacement............................................................................................................................................

Stoning the Commutator ...................................................................................................................................

Motors Repair.....................................................................................................................................................

Disassemble ...................................................................................................................................................

Traction Motor and Hydraulic Pump Motor ............................................................................................

Steering Pump Motor ................................................................................................................................

Assemble ........................................................................................................................................................

Traction Motor and Hydraulic Pump Motor ............................................................................................

Steering Pump Motor ................................................................................................................................

Brush Alignment, Traction and Hydraulic Motors ..........................................................................................

Tests for Damaged Field and Armature ...........................................................................................................

Test for an Open Circuit in Armature ..........................................................................................................

Test for Short Circuit in One Armature Winding ........................................................................................

Test for Short Circuit to Armature Shaft .....................................................................................................

Test for Open Circuit in Field Coil................................................................................................................

Test for Short Circuit in Field Coil ...............................................................................................................

Test for Short Circuit between Field and Motor Case .................................................................................

Brush Holder Test..........................................................................................................................................

Troubleshooting..................................................................................................................................................

1 1 1 4 4 4 8 10 12 12 12 16 16 16 17 20 20 20 21 21 21 21 22 22 22

This section is for the following models: All Electric Lift Trucks

©2003 HYSTER COMPANY

i

620 SRM 294

Brush and Commutator Inspection

General This section describes disassembly and assembly, brush installation, inspection, and checks for malfunctions of DC motors. Inspect the commutator and brushes every 350 hours of operation. The commutator is the rotating electric connection between the armature and the electric power supplied by the battery. Brushes made of carbon compounds slide on the rotating commutator and are the path for electricity from the battery to the commutator and the armature. The maintenance of the commutator and the brushes is important to the good operation of a DC motor.

Traction motors and hydraulic pump motors are similar in design. The hydraulic pump motors are smaller than the traction motors, but the disassembly and maintenance of these motors are similar.

The cooling fan in the traction motors is fastened to the armature and can be removed from the armature. The cooling fan can be removed during disassembly of the traction motor.

The cooling fan in the hydraulic pump motors can be a press fit on the armature shaft and is not easily removed during disassembly of the motor. The armature and cooling fan must be removed from the drive end of the motor during disassembly.

The assembly and disassembly of the motor used for the power steering pump is described in the Steering System section. This motor is a permanent magnet motor.

Brush and Commutator Inspection HYDRAULIC PUMP MOTOR AND TRACTION MOTOR NOTE: The brushes and commutator can be inspected, the brushes can be replaced, and Stoning the Commutator can be done with the motor installed in the truck.

NOTE: Inspect the brushes and commutator every 350 hours for best operation and to prevent motor damage. The hydraulic pump motor normally has more start cycles than other motors, so it can have more wear and possible damage.

NOTE: The following procedure is for inspecting the brushes and commutator with the motor installed in the lift truck. The same inspections can be done with the motor removed. If the motor is removed, start at Step 3.

1. To rotate the commutator of the traction motor without moving the truck, the drive wheels must be raised. See Figure 1. Raise drive wheels so commutator of the traction motor can be rotated without moving lift truck. See How To Raise Drive Wheels in the Operating Manual or the Periodic Maintenance SRM section for your lift truck.

1. ARMATURE (DRIVE) SHAFT

2. COOLING FAN 3. BRUSH COVER

Figure 1. Traction Motor NOTE: For some models of lift trucks, the battery does not need to be removed to access the electric motors. Other models will require the removal of the battery before gaining access to the electric motors.

To remove the battery, either raise the hood panels or unfasten the floor plate, depending on which motor needs to be accessed.

2. Remove battery. See How to Remove Battery in the Operating Manual or the Periodic Maintenance SRM section for your lift truck.

Remove access plate to motors. If the battery in your lift truck does not need removal for access to the motors, go to Step 3.

1

Brush and Commutator Inspection

620 SRM 294

WARNING Compressed air can move particles so that they cause injury to the user or to other personnel.

Make sure that the path of the compressed air is away from all personnel. Wear protective goggles or a face shield to prevent injury to the eyes.

NOTE: Vacuum cleaning, when possible, is the recommendation of manufacturers of electric motors.

The use of compressed air can send dirt particles into the bearings and other areas of the motor that can cause possible damage.

3. Remove brush covers at rear of motor. See Figure 2. Wear eye protection. Use a vacuum cleaner or compressed air to remove dirt and brush dust from commutator area.

1. BRUSH 2. BRUSH SPRING

3. MICA

Figure 3. Brush Removal and Inspection

Figure 2. Brush Cover Removal From Motor 4. Remove and inspect brushes for damage or uneven wear. Replace all brushes if any brush is worn or damaged. The brushes must be at least half their original length. Move brush springs away from top of each brush and pull brushes from their holders to inspect surface that rides on commutator. See Figure 3. That surface must have the same shape as the commutator and must not have cracks or defects. Some brushes have wear sensor wires attached, even if they are not connected to an indicator. Replace these brushes if brushes are worn enough to see sensor at commutator end of brush.

2

5. Inspect commutator surface. See Table 1 and Table 2. Carefully rotate armature. DO NOT damage commutator if you use a tool to rotate armature.

The commutator wears slowly in normal service.

The mica must be cut below the surface of the commutator bars after a long service period or after a commutator has been turned in a lathe.

A commutator that has been in service will have a smooth and polished surface with a darker brown color where it rotates under the brushes.

A variation of color on the commutator surface between light brown and darker brown is normal. The surface condition is the lubrication between the commutator and the brushes. The brushes will wear rapidly if this surface condition does not develop during the first 6 to 10 hours of operation after a commutator with a new surface is installed. If the commutator has deep grooves, rough edges of the bars, or a few bars that are black or raised above the others, the motor must be removed for service.

620 SRM 294

Brush and Commutator Inspection

6. Inspect white or gray insulation (mica) between commutator bars. The mica must not touch the brushes or the brushes will wear very rapidly.

touches commutator. Make sure the springs are pushing on each brush. Install and tighten screws for brush wires and bus connectors.

7. To replace a brush set, remove screw that holds brush wires to bus. Pull brush end of springs from brushes, and pull brushes from holders.

Lift brush springs away from holders, and install new brushes so brush commutator surface fully

8. Carefully install brush covers so sparks are kept inside motor housing. Install battery as described in Operating Manual or the Periodic Maintenance SRM section for your lift truck.

Table 1. Normal Commutator Surfaces A light brown surface of the commutator where it rotates on the brushes is a normal condition. The surface of the commutator must be smooth.

Variations between light brown and dark brown colors are also normal. The surface of the commutator must be smooth.

A condition called slot bar marking is also normal if the commutator surface is smooth. The variable color occurs in a pattern according to the number of conductors per slot.

A very dark surface is also a normal and an acceptable condition if the commutator surface is smooth.

3

Brush and Commutator Inspection

620 SRM 294

STEERING PUMP MOTOR

NORMAL COMMUTATOR SURFACE

NOTE: Some electrical trucks use a steering pump motor. Refer to your truck model’s service manual for instructions on removal and installation of steering pump motors.

A commutator that has been in service will have a smooth and polished surface with a darker brown color where it rotates under the brushes. See Table 1. A variation of color on the commutator surface between light brown and darker brown is normal.

This surface condition is the lubrication between the commutator and the brushes. The brushes will wear rapidly if this surface condition does not develop during the first 6 to 10 hours of operation after a commutator with a new surface is installed.

1. Disconnect battery connector. Remove floor plate from lift truck for access to steering pump motor.

Open hood for access to motor. Remove screws that hold two brush cover plates to motor housing.

2. Inspect brushes and commutator as described in previous paragraphs for traction and hydraulic pump motors. The brush replacement procedure is also the same, although there are only two brushes for the steering pump motor. See Table 3.

COMMUTATOR PROBLEMS Commutator and motor problems and are shown in Table 2.

3. Install brush covers and screws. Install floor plate or close hood and connect battery connector.

Table 2. Commutator Problems Problem

Possible Cause

Heavy streaks and fine grooves indicate the beginning of damage to the commutator.

• Operation of the motor in dirty and abrasive conditions.

• Continuous operation of a motor with a light load.

• Brush pressure is too low.

• Worn brushes.

4

Illustration

620 SRM 294

Brush and Commutator Inspection

Table 2. Commutator Problems (Continued) Problem

Possible Cause

Grooves and lines that have followed the heavy streaks and fine grooves shown above.

The armature must be removed from the motor so the commutator can be repaired. A commutator with this condition will cause the brushes to wear rapidly.

• Operation of the motor in dirty and abrasive conditions.

• Continuous operation of a motor with a light load.

• Brush pressure is too low.

• Worn brushes.

Grooves that are the width of the brushes.

• Operation of the motor in dirty and abrasive conditions.

• Wrong type of brushes for this motor and operation.

• Brush pressure is too high.

A condition called copper drag occurs when copper from the commutator bar is pulled into the slot between the commutator bars. This condition will cause a short circuit between the commutator bars if it is not corrected.

The brushes will wear rapidly.

• Operation of the motor in dirty and abrasive conditions.

• Brush holder is not adjusted electrically correct for the motor.

• Wrong type of brushes for this motor and operation.

• Brush pressure is wrong (too high or too low).

Illustration

5

Brush and Commutator Inspection

620 SRM 294

Table 2. Commutator Problems (Continued) Problem

Possible Cause

Electrical burns on commutator bars on opposite sides of the commutator.

• Open armature winding.

• Motor has been stalled.

Copper wears rapidly at the edge of the commutator bars.

• Operation of the motor in dirty and abrasive conditions.

• Wrong type of brushes for this motor and operation.

6

Illustration

620 SRM 294

Brush and Commutator Inspection

Table 2. Commutator Problems (Continued) Problem

Possible Cause

1. Flashover causes burning of the ends of the commutator bar.

2. Open circuit in winding causes deep burning of adjacent commutator bars.

3. Overheating causes damage to varnish insulation.

• Motor has been too hot. Wrong lift truck for the application.

• Motor has been stalled.

• Open armature winding.

• Open field coil.

Brush and commutator damage occurs when the high commutator hits and forces the brush up. Arcing and burns occur as the brush moves back down to the normal surface.

Check for loose or high commutator bars.

• Motor has been stalled. (High commutator bars at each brush position can occur if the motor is stalled.)

• Motor has been too hot.

Illustration

1. High commutator bars at each brush position can occur if the motor is stalled.

2. Rapid brush wear from high commutator bars.

7

Brush Replacement

620 SRM 294

Brush Replacement 1. Motor brushes must be replaced before they are worn enough to damage the surface of the commutator. Move the brush spring and remove a brush from its brush holder. Install new brushes as a set if length of any brush is worn to a minimum length. See Table 3. If the brush lead is fastened to the brush with a rivet, install a new set of brushes if it is worn to within 3 mm (0.118 in.) of the rivet. If a brush does not move easily in its holder, a new set of brushes must be installed.

The lead wire for some brushes is installed directly into the carbon compound of the brush.

New brushes must be installed before the lead wire cuts a groove in the commutator. Install a new brush set when a brush is worn to a short length.

Brushes are made to different specifications for motors used in different applications. Use only new brushes approved by Hyster Company for that motor.

NOTE: For some models of lift trucks, the battery does not need to be removed to access the electric motors. Other models will require the removal of the battery before gaining access to the electric motors.

2. Remove battery as necessary for your lift truck.

See How To Remove Battery in the Operating Manual or the SRM section Periodic Maintenance for your lift truck.

WARNING Compressed air can move particles so they cause injury to the user or to other personnel.

Verify the path of the compressed air is away from all personnel. Wear protective goggles of a face shield to prevent injury to the eyes.

3. Remove access plate to motors. Remove brush covers to motor. See Figure 2. Wear eye Use a vacuum cleaner or comprotection. pressed air to remove dirt and brush dust from commutator area.

4. Make a note of the arrangement and connections of the brush assembly. See Figure 4. The new brushes must be installed in the same positions from which the worn brushes were removed.

5. Loosen screw that fastens brush wire to its terminal. Remove brush springs and brushes.

6. Inspect brush holders for burns and damage.

Make sure brush holders are fastened tightly to brush mounting plate at end of motor. Make sure new brushes will move freely and smoothly in brush holders. Check that brush mounting plate is holding brush holder so it does not move.

7. Connect new brush wire to its terminal mount.

Table 3. Brush Wear Replacement Guide Brush Height

17 mm (0.67 in.)

22 mm (0.87 in.)

28 mm (1.10 in.)

30 mm (1.18 in.)

31 mm (1.22 in.)

32 mm (1.26 in.)

40 mm (1.57 in.)

Wear

8 mm (0.31 in.)

12 mm (0.47 in.)

14 mm (0.55 in.)

15 mm (0.59 in.)

16 mm (0.63 in.)

16 mm (0.63 in.)

16 mm (0.63 in.)

Worn Brush Height

9 mm (0.35 in.)

10 mm (0.39 in.)

14 mm (0.55 in.)

15 mm (0.59 in.)

15 mm (0.59 in.)

16 mm (0.63 in.)

20 mm (0.79 in.)

8

620 SRM 294

Brush Replacement A brush for a traction motor has an area of approximately: 5.33 × 1.27 cm = 6.8 cm 2 (2.1 × 0.5 in. = 1.05 in 2).

Brush springs for the traction motor normally have a spring force of approximately: 9.1 to 11.3 Newtons (36 to 44 ozf) when measured with a spring scale as shown in Figure 5.

A brush for a hydraulic pump motor has an area of approximately: 4.42 × 0.95 cm = 4.21 cm 2 (1.74 × 0.375 in. = 0.653 in 2).

Brush springs for the hydraulic pump motor normally have a spring force of approximately: 5.2 to 7.4 Newtons (20 to 28 ozf) when measured with a spring scale as shown in Figure 5.

1.

2.

3.

4.

BRUSH BRUSH BRUSH BRUSH

HOLDER (4) MOUNTING PLATE SPRING (4) SET Figure 4. Brush Assembly

NOTE: When new brushes must be installed, a recommendation is to also install new brush springs.

Damage from heat can cause the brush springs to have the wrong spring pressure.

8. Check brush springs for damage from heat and corrosion. If brush springs are damaged, install new brush springs. Check brush springs for approximately equal pressure.

Brush springs normally have a spring pressure of approximately: 1.0 to 2.0 Newtons per each cm 2 (1.5 to 3.0 lbf per each in 2) when measured with a spring scale.

NOTE: SOME MOTORS HAVE SPRINGS AS SHOWN IN FIGURE 7 AND FIGURE 11. SOME SPRINGS ARE IN PAIRS AT EACH BRUSH HOLDER. 1. SPRING SCALE 2. BRUSH IN BRUSH HOLDER

3. COMMUTATOR 4. BRUSH SPRING

Figure 5. Brush Spring Pressure Check

9

Stoning the Commutator

620 SRM 294

WARNING Wear eye protection. Raise the drive wheels.

Operate the motor at low speed. Protect your fingers. You are doing work close to moving parts of the motor. Do not use a brush seater stone less than 60 mm (2.4 in.) in length.

NOTE: The brush springs used in motors made by Hyster have a constant force design. The force of the brush spring against the brush stays almost constant as the brush wears and becomes shorter in its brush holder.

NOTE: New brushes made by the manufacturer are normally made to fit the surface of the commutator when they are installed. This contact surface must be checked when new brushes are installed. The contact surface MUST be approximately 85 percent of the brush surface where it touches the commutator.

A small contact surface can cause burns and a rough surface on the commutator. If the contact surface is less than approximately 86 percent, the new brushes must be made to fit the commutator better.

9. If new brushes must be made to fit the surface of the commutator, see Stoning the Commutator.

Use a Brush Seater and Commutator Stone (No. 23-007M from the Ideal Company or an equivalent brush seater stone). Stoning the commutator is most easily done when the motor rotates slowly. When the motor rotates at higher speeds, the centrifugal force removes the abrasive particles from the commutator more quickly.

NOTE: To rotate the commutator of the traction motor without moving the truck, the drive wheels must be raised. See How to Raise Drive Wheels in the Operating Manual or the SRM section Periodic Maintenance for your lift truck.

Stoning the Commutator 1. If the commutator has grooves or other damage, the armature must be removed so the commutator can be repaired. Motors are normally repaired by service persons that have the special equipment required. Connect battery so the motor can be operated. See Figure 6. The battery must be removed for access to the motor. Use a jumper cable to connect battery to lift truck.

Raise drive wheels. See How to Raise the Drive Wheels in the Operating Manual or the SRM section Periodic Maintenance for your lift truck.

2. Close seat switch and key switch so motor will operate.

NOTE: A brush seater stone can also be fastened to a wood stick with glue as shown in Figure 6. This arrangement makes it easier to apply a brush seater stone in small spaces.

3. Operate motor so commutator rotates slowly.

Apply brush seater stone to moving commutator with light pressure. Move brush seater stone backward and forward across surface of commutator until marks on commutator are removed.

10

Apply brush seater stone to commutator before each set of brushes so the brush seater particles have an even distribution.

CAUTION Do not permit the brush seater stone to stay in contact with the commutator too long and cause more wear than necessary.

4. Turn key switch to OFF position and disconnect battery. Check all brush contact surfaces. The brushes fit correctly when 85 percent of the brush contact surface touches the commutator.

This stoning procedure normally requires approximately 15 to 45 minutes.

5. When the brushes have the correct contact surface with the commutator, use a vacuum cleaner to remove abrasive dust from commutator area and motor.

6. When the installation and checks are complete, install brush cover. Make sure wires to brushes do not touch any part of motor case and cause a short circuit.

620 SRM 294

Stoning the Commutator Legend for Figure 6 1. RAISE DRIVE WHEELS 2. JUMPER

3. BATTERY 4. BRUSH SEATER STONE

Figure 6. Stoning the Commutator

11

Motors Repair

620 SRM 294

Motors Repair DISASSEMBLE See the section Master Drive Unit or Frame for your lift truck for instructions on the removal and installation of the traction motor.

See the Hydraulic System section for instructions to remove and install the hydraulic pump and motor.

See the Brush and Commutator Inspection and Brush Replacement in this section for more information on these components of the motor.

Traction Motor and Hydraulic Pump Motor 1. Clean outside surfaces of motor before disassembly. See Figure 8, Figure 9, and Figure 10.

Put motor on its commutator (brush) end on a bench. On hydraulic motor assemblies, make index marks on pump and motor. Make index marks on end frames of motor and field frame so correct assembly is possible.

2. On hydraulic motor assemblies, remove two capscrews that fasten pump to pump motor. See Figure 11 or Figure 12. Remove pump. Put an index mark on armature shaft at the position of the coupler hub for correct assembly. Remove coupler hub from armature shaft by loosening setscrew and sliding hub off shaft and key. Do not lose key.

6. Remove drive end frame from armature.

If the brush holder (1) must be loosened or removed from the end frame for repairs, the brush holder must be installed again in the same position. See Figure 7. Make alignment marks between the brush holder and the end frame before the brush mounting plate (4) is released. The brush holder must be installed again in the same position.

If a new brush holder must be installed, there will not be an alignment mark on the new brush holder. Make an alignment mark on end frame with a reference point on brush holder that must be removed. Install new brush holder so reference point and alignment mark are aligned. The new brush holder must be installed in the same position as the old holder so the timing will be correct.

7. Remove screws that fasten brush holder assembly to commutator end frame.

8. Disassemble components of motor as necessary to make repairs.

3. Remove brush cover. Remove brushes and spring assemblies.

4. Remove hex head screws from commutator end of motor. Carefully slide end frame from motor and armature shaft. Do not damage parts. A puller is frequently necessary to separate end frame from field frame.

CAUTION The drive end frame and the armature are heavy components. Work carefully so the field coils, pole pieces, and armature are not damaged during disassembly and assembly.

5. Remove screws that fasten drive end frame to field frame. Remove end frame and armature.

Use a plastic or rubber hammer as necessary to loosen end frame.

12

1. BRUSH HOLDER 2. BRUSH SPRING

3. BRUSH 4. BRUSH MOUNTING PLATE

Figure 7. Brush Holder and Mounting Plate

620 SRM 294

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

Motors Repair

FIELD FRAME ASSEMBLY ARMATURE BRUSH SPRING (4) BRUSH (4) BEARING BEARING DRIVE END FRAME COMMUTATOR END FRAME SCREW (4) SCREW (4) WASHER (8) WASHER FAN COVER BRUSH COVER

15.

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24.

25.

26.

27.

SCREW (4) WASHER (4) FAN HUB FAN SCREW (2) SNAP RING OIL SEAL BRUSH HOLDER SCREW (4) WASHER (4) BRUSH MOUNTING PLATE MOUNT PLATE SCREW (4)

Figure 8. Typical Traction Motor (Example 1)

13

Motors Repair

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SNAP RING BEARING SEAL DRIVE END FRAME FAN COVER SNAP RING FAN KEY ARMATURE BEARING

620 SRM 294

11.

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14.

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16.

17.

18.

19.

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BRUSH COVER COMMUTATOR END FRAME TERMINAL BRUSH MOUNTING PLATE BUS CONNECTOR WIRE BRUSH SPRING BRUSH BRUSH HOLDER FIELD FRAME

Figure 9. Typical Traction Motor (Example 2)

14

620 SRM 294

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4.

5.

6.

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8.

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BAND SPRING DRIVE END PLATE SCREW WASHER FAN RING ARMATURE FIELD COIL (FRAME) POLE SHOE HOUSING TUBE HEX HEAD BOLT SCREW LOCKWASHER

Motors Repair

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DISC BRUSH SPRING BRUSH SCREW DISC (SPRING) BRUSH HOLDER CIRCLIP BALL BEARING END PLATE (CPL) END FRAME (COMMUTATOR) HEX HEAD BOLT LOCKWASHER RING SPRING BRUSH COVER

Figure 10. Typical Traction Motor (Example 3)

15

Motors Repair

Steering Pump Motor NOTE: Some lift trucks could be equipped with a Brushless DC Power Steering motor, which is non-repairable.

NOTE: Some electrical trucks use a steering pump motor. Refer to the service manual for your truck model for instructions on the removal and installation of steering pump motors.

1. See Power Steering Motor and Pump for the removal and installation procedures for the steering pump motor. Make index marks on the steering pump and the drive end frame of the motor. Remove two capscrews that hold steering pump to motor. Remove pump and allow oil to drain from drive end frame.

2. Remove brush covers. See Figure 2. Remove two screws that hold brushes and terminal wires to brush holders. Pull brush springs out of the way and pull two brushes from holders.

3. Make alignment marks on commutator end frame and field frame. Remove four long screws that hold commutator end frame to drive end frame. Pry commutator end frame from field frame. The bearing will stay with the armature.

Make sure the special spring stays in the end frame.

4. Make alignment marks on drive end frame and on field frame. Use a soft hammer to tap drive end frame from field frame. The bearing will stay with the armature.

5. Pull armature assembly from field frame. The force of the permanent magnets in the frame makes it difficult to remove the armature. Use a pry bar to help move armature assembly.

16

620 SRM 294 6. Make alignment marks on brush holder plate and on commutator end frame. Remove two screws that hold brush plate to commutator end frame. Remove brush holder assembly.

ASSEMBLE Traction Motor and Hydraulic Pump Motor 1. Make sure all components are clean. If bearings were worn, install new bearings in end frames.

See Figure 8 or Figure 9.

2. If cooling fan was removed, install it on armature. Make sure field coils and pole pieces are installed correctly in field frame.

3. Install brush holder assembly in commutator end frame. Make sure alignment marks are aligned.

4. Install drive end frame on armature.

5. Carefully install armature and drive end frame in field frame. Make sure index marks are aligned. Install and tighten screws.

6. Carefully install commutator end frame on armature and fasten it to field frame. Install and tighten hex head screws.

7. Install brushes and spring assemblies. See Brush Replacement and Brush Alignment, Traction and Hydraulic Motors in this section.

8. On hydraulic motor assemblies, install key and coupler hub to index mark on armature shaft.

Tighten setscrew. Install other key and align pump with coupler and alignment marks. Install two capscrews that fasten pump to pump motor.

See Figure 11, Figure 12, or Figure 13.

620 SRM 294

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2.

3.

4.

5.

6.

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8.

Motors Repair

BRUSH COVER COMMUTATOR END FRAME TERMINAL BRUSH BRUSH HOLDER BRUSH SPRING (8) BUSH CONNECTOR (2) FIELD COILS

9.

10.

11.

12.

13.

14.

15.

16.

BEARING ARMATURE FAN BEARING DRIVE END FRAME FAN COVER WOODRUFF KEY FIELD FRAME

Figure 11. Typical Hydraulic Pump Motor (Example 1)

Steering Pump Motor NOTE: Some lift trucks could be equipped with a Brushless DC Power Steering motor, which is non-repairable.

NOTE: Some electrical trucks use a steering pump motor. Refer to your truck’s service manual for instructions on the removal and installation of steering pump motors.

1. Replace seal in drive end frame. Replace bearings on armature by pushing only on inner races.

2. Install armature into field frame so commutator is aligned with brush inspection openings in field frame.

3. Lubricate seal lip with hydraulic oil. Align index marks and carefully install drive end frame on armature and field frame assembly.

4. Align index marks and install brush holder assembly in commutator end frame. Install and tighten two screws.

17

Motors Repair

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7.

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620 SRM 294

9.

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WOODRUFF KEY FAN COVER DRIVE END FRAME BEARING FAN WOODRUFF KEY ARMATURE BEARING

TERMINAL ASSEMBLY BRUSH COVER COMMUTATOR END FRAME BRUSHES BRUSH HOLDER ASSEMBLY BRUSH SPRING BUS CONNECTOR FIELD FRAME

Figure 12. Typical Hydraulic Pump Motor (Example 2) 5. Make sure special spring is in position in commutator end frame. Align index marks and install commutator end frame. Carefully install four long screws through field frame into drive end frame. Tighten screws.

6. Install brush springs and brushes. Make sure angle of brush is in correct position on commutator. Put end of brush spring on each brush.

18

Connect brush wires and wires for terminals to correct brush holder. Install brush covers.

7. Install new O-ring on mounting surface of pump and align index marks. Align pump drive tang with armature and install pump on motor. Install and tighten capscrews.

620 SRM 294

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Motors Repair

DRIVE END COVER ARMATURE TOLERANCE RING FIELD COIL POLE PIECE (4) HOUSING HEX HEAD BOLT (8) BRUSH COVER BRUSH PLATE BRUSH HOLDER (4)

11.

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BRUSH SPRING (4) BRUSH (4) SCREW (4) WASHER BRUSH TERMINAL END PLATE (COMMUTATOR CPL) END PLATE FAN SHROUD (FAN)

Figure 13. Typical Hydraulic Pump Motor (Example 3)

19

Tests for Damaged Field and Armature

620 SRM 294

Brush Alignment, Traction and Hydraulic Motors NOTE: The brush holder in these motors can be rotated for timing of the brush alignment with the commutator. This process normally requires special equipment and training. A special repair service for electric motors is required to align the bushes for the correct timing with the commutator. If the brushes are not timed correctly with the commutator, the motor will have a low power output. The procedures for timing an electric motor are not described in this section. Do not rotate the brush holder from its original position.

If the brush holder must be loosened or removed from the end frame for repairs, the brush holder must be

installed again in the same position. See Figure 7.

Make alignment marks between brush holder and end frame before brush mounting plate is released.

The brush holder must be installed again in the same position.

If a new brush holder must be installed, there will not be an alignment mark on the new brush holder.

Make an alignment mark on end frame with a reference point on brush holder that must be removed. Install new brush holder so the reference point and the alignment mark are aligned. The new brush holder must be installed in the same position as the old holder so the timing will be correct.

Tests for Damaged Field and Armature The tests described in the following paragraphs are to help a service person check a motor for damage and to determine if it must be sent to a repair service for rebuilt motors. The resistance checks will not normally indicate a short circuit in a motor winding. A resistance greater than 1 to 2 ohms can indicate a damaged winding. The motor must be removed from the lift truck and disassembled as shown in the illustrations before the tests can be done.

TEST FOR AN OPEN CIRCUIT IN ARMATURE The armature windings in large electric motors normally have less than 1 ohm of resistance. The two commutator bars for a winding are found 180 degrees apart on the commutator. If an ohmmeter (R × 1 scale) is used to check the resistance between the two commutator bars of the winding, a resistance of more than 1 ohm indicates a problem in that winding. A resistance of infinity (∞) indicates an open (damaged) winding. See Figure 14 and Figure 15.

1. COMMUTATOR BARS 2. TEST PROBES AT 90 DEGREE SEPARATION Figure 14. Test for an Armature Open Circuit

If the armature has an open circuit, there will normally be two burned commutator bars on opposite sides of the commutator. These burned areas will cause the brushes to wear rapidly. When the motor operates, large electric sparks and arcs occur as the damaged commutator bars rotate under each brush.

See Table 2.

1. COMMUTATOR BARS 2. TEST FOR SHORT CIRCUIT BETWEEN WINDINGS Figure 15. Test All Armature Windings

20

620 SRM 294

TEST FOR SHORT CIRCUIT IN ONE ARMATURE WINDING A short circuit in a motor winding is difficult to test because of the normal low resistance (less than 1 ohm) of a good armature. Special equipment is necessary to check for a short circuit in a motor winding.

A motor with a short circuit in an armature winding will have a different sound when it begins to operate, but a service person must have experience to hear and understand the difference in sound. A winding with a short circuit will also run hotter than a good winding and can have indications of heat damage.

A winding that shows heat damage when the other windings are normal can have a short circuit.

Tests for Damaged Field and Armature have a different sound when it begins to operate, but a service person must have experience to hear and understand the difference in sound. A winding with a short circuit will also run hotter than a good winding and can have indications of heat damage.

Another indication of a short circuit will be a higher than normal current draw by the motor. A higher than normal current draw can also indicate other problems or needed adjustments and does not always indicate a short circuit in a motor winding.

Another indication of a short circuit will be a higher than normal current draw by the motor. A higher than normal current draw can also indicate other problems or needed adjustments and does not always indicate a short circuit in a motor winding.

TEST FOR SHORT CIRCUIT TO ARMATURE SHAFT NOTE: Clean the dirt and brush dust from the commutator area before making a test for a short circuit.

An ohmmeter (R × 10,000 scale) can be used to test for a short circuit between an armature winding and the armature shaft. Put one probe on the armature shaft and the other probe on a commutator bar. See Figure 16. A resistance of less than 1 megohm indicates a problem between a winding and the armature shaft.

1. ARMATURE SHAFT 2. COMMUTATOR

3. PROBES TO OHMMETER

Figure 16. Test for Armature Short Circuit

TEST FOR OPEN CIRCUIT IN FIELD COIL The field windings in large electric motors normally have less than 1 ohm of resistance. If an ohmmeter (R × 1 scale) is used to check the resistance between the two terminals of the winding, a resistance greater than 1 ohm indicates a problem in that winding or corrosion in the terminal connection. See Figure 17.

TEST FOR SHORT CIRCUIT IN FIELD COIL A short circuit in a motor field winding is difficult to test because of the normal low resistance (less than 1 ohm) of a good field. Special equipment is necessary to check for a short circuit in a motor winding.

A motor with a short circuit in a field winding will

1. FIELD COIL TERMINAL

2. OHMMETER

Figure 17. Test for Open Field Circuit

21

Troubleshooting

620 SRM 294

TEST FOR SHORT CIRCUIT BETWEEN FIELD AND MOTOR CASE

1 megohm indicates a problem between the field terminal and the motor case.

Make sure that carbon dust has been cleaned from the motor before making this test. An ohmmeter (R × 10,000 scale) can be used to test for a short circuit between the field and the motor case. Put one probe on the motor case and the other probe on a field terminal. Check the resistance between the field terminal and the motor case. A resistance of less than

BRUSH HOLDER TEST Make sure the carbon dust has been removed from the brush holders. Use an ohmmeter (R × 10,000 scale) to measure the resistance between the brush holder and the motor case. The correct resistance is an indication of infinity (∞).

Troubleshooting PROBLEM Heavy streaks and grooves (see Table 2).

POSSIBLE CAUSE fine

Grooves and lines following heavy streaks. The armature must be replaced or the brushes will wear rapidly (see Table 2).

Grooves the width of the brushes (see Table 2).

22

PROCEDURE OR ACTION

Operation in a dirty or abrasive environment.

Clean commutator more frequently.

Continuous operation of motor with a light load.

Increase load on motor from time to time.

Brush pressure is too low.

Increase brush pressure.

Worn brushes.

Replace brushes.

Operation in a dirty or abrasive environment.

Clean commutator more frequently.

Continuous operation of motor with a light load.

Increase load on motor from time to time.

Brush pressure is too low.

Increase brush pressure.

Worn brushes.

Replace brushes.

Operation in a dirty or abrasive environment.

Clean commutator more frequently.

Wrong type of brushes for this motor and operation.

Replace brushes with correct type.

Brush pressure is too high.

Adjust brush pressure.

620 SRM 294

PROBLEM Copper drag occurs when copper from the commutator is pulled into the slot between the commutator bars.

This problem will cause a short circuit between the commutator bars (see Table 2).

Electrical burns on commutator bars on opposite sides of the commutator (see Table 2).

Copper wears rapidly at the edge of the commutator bars (see Table 2).

Troubleshooting

POSSIBLE CAUSE

PROCEDURE OR ACTION

Operation in a dirty or abrasive environment.

Clean commutator more frequently.

Brush holder is not correctly adjusted electrically for the motor.

Adjust brush holder.

Wrong type of brushes for this motor and operation.

Replace brushes with correct type.

Brush pressure is incorrect (too high or too low).

Adjust brush pressure.

Open armature winding.

Replace armature.

Motor has been stalled.

Use correct operating techniques.

Operation in a dirty or abrasive environment.

Clean commutator more frequently.

Wrong type of brushes for this motor and operation.

Replace brushes with correct type.

23

Troubleshooting

PROBLEM

620 SRM 294

POSSIBLE CAUSE

PROCEDURE OR ACTION

Burning/Overheating 1. Flashover causes burning of the commutator bar.

2. Open circuit in winding causes deep burning of adjacent commutator bars.

3. Overheating causes damage to varnish insulation (see Table 2).

Motor has been too hot.

Wrong lift truck for the application.

Motor has been stalled.

Open armature winding.

Open field coil.

Use correct lift truck for the application.

Use correct operating techniques.

Replace armature or resurface commutator in a lathe.

Replace field coil.

Commutator bars are either too high or too loose, both of which can cause damage to brushes (see Table 2).

Motor has been stalled.

Use correct operating techniques.

Motor has been too hot.

Use correct lift truck for the operation.

24

CHECKS AND ADJUSTMENTS GENERAL This section has the checks and adjustment procedures for some of the electrical parts on the R30E, R30EA and R30EF units. There are also repair procedures for these parts. See the section ELECTRIC POWER STEERING, 1600 SRM 418 for the description, adjustment and repair of the electrical parts of the steering system. Use the procedures in the section BATTERY INDICATORS, 2200 SRM 138 to replace and adjust the battery indicator. See the sections WIRE GUIDANCE — Description, 2200 SRM 421 and WIRE GUIDANCE — Repair, 2200 SRM 422 for the description, adjustment and repair of the optional guidance system parts.

NOTE: NEVER make adjustments if the system or component is operating correctly.

WARNING Do not operate a lift truck that needs adjustment or repairs. Report the need for adjustment or repairs immediately. If adjustment or repair is necessary, put a “DO NOT OPERATE” tag in the operator’s area. Remove the key from the key switch.

CONTROL AND POWER FUSES (See Figure 1) The control fuse (FU 3) is near the key switch in an inline fuse holder in the instrument panel. The fuse (FU 5) for the optional fan and light circuit is also an in-line fuse in the instrument panel. Remove the screws at the top edge of the instrument panel to open the instrument panel for access. The steering wheel or handle must also be removed. The power fuses; traction circuit (FU 1) and pump motor (FU 2), are next to the pump contactor.

See Figure 1. Remove the cover over the electrical compartment for access. The fuse for the steering gearmotor (FU 4) is in the in-line fuse holder near the Electronic Control Module (ECM). The condition of the fuses can normally be checked by looking at them. Some fuses do not change in looks and must be checked with an ohmmeter. Disconnect the battery before checking fuses.

Sizes of the fuses are as follows: FU-1 power fuse (Traction Circuit) FU-2 power fuse (Pump Motor) FU-3 control fuse FU-4 steering gearmotor FU-5 optional fan and light

Some of the checks and adjustments are done with the battery connected. Never have any metal on your fingers, arms or neck. These metal items can accidentally make an electrical connection and cause an injury.

CAUTION Correct meter polarity is necessary for some checks. Meter correct positive is indicated as (+).

Meter correct negative is indicated as (-).

Use a meter with a minimum rating of 20 000 ohms per volt to make measurements. Most digital voltmeters are good.

FIGURE 1. POWER FUSE LOCATIONS

300A 500A 15A 35A 15A

EV-100 MOTOR CONTROLLER (See Figures 2 and 3) NOTE: To check and replace the EV-100 Traction motor controller card or other parts, see the section EV100 Repair, 2200 SRM 288.

tion/speed control is moved a small amount. The fastest minimum speed occurs when the “CREEP” potentiometer is adjusted to the “9” position. Very rough operation will occur if this lift truck has a setting much above the normal setting shown in Figure 3.

Control card adjustment is required when traction motor circuit parts are replaced. Adjustment can be required for different performance needs. For access to the adjustment screws on the control cards, slide the cover off. See Figure 2. Use a small screwdriver to turn the adjustment screw counterclock wise to the stop. Use the end of the screw slot at the “1” position for the reference. Turn the adjustment screw to the correct setting shown in Figure 3 or described in the procedure.

NOTE: A decal in the electrical compartment has the factory settings of the adjustment screws for the control card.

NOTE: Make sure the battery has a corrected spe- FIGURE 2. ADJUSTMENT SCREW COVERS, cific gravity of at least 1.250.

TRACTION CONTROL CARD EV-100 Traction Control Card (See Figures 2 And 3) CAUTION The “C/L’, “potentiometer must be adjusted to the factory setting shown in Figure 3. The “CREEP”, “C/A” and “PLUG” potentiometers can be adjusted for specific applications.

ADJUST CONTROLLED ACCELERATION, ”C/A”

The “C/A” adjustment sets the maximum acceleration rate for the lift truck. The “C/A” circuit prevents SCR 1 pulses from increasing average motor voltage too fast when the control lever is moved quickly. If the setting is too low, the lift truck will accelerate too slowly. If the setting is too high, the traction motor brushes will wear NOTE: This lift truck does not have the 1A, or Field too fast. The setting shown in Figure 3 provides normal Weakening functions, so the “1A TIME”, “F.W.P.U.” acceleration. The fastest acceleration occurs when the and “F.W.D.O.” settings are not necessary. Set these “C/A” is set to the “9” position. Very rough operation trimpots at the minimum setting. will occur if this lift truck has a setting much above the normal setting shown in Figure 3.

ADJUST CREEP SPEED, “CREEP” ADJUST CURRENT LIMIT, “C/L” The “CREEP” speed adjustment sets the minimum speed for the lift truck. At the correct setting, the SCR will The current limit potentiometer controls the maxi-mum hum, but the lift truck will not quite move as a direction current going to the traction motor. The ad-justment sets contactor first energizes. A very slow speed is good for the point at which the circuit for the current control overmost operations. The setting shown in Figure 3 is cor- rides the pulse circuit. The “C/L” potentiometer must rect for normal operations. The lift truck must move be adjusted to the setting shown in Figure 3. smoothly when the direc-

(4500 to 5500) ohms as the forward switch just makes contact. Check that the reading decreases smoothly with no flat areas or infinity readings as the direction/speed control is moved to the maximum position. Do the checks again for the reverse direction. The two resistance readings must be equal within 10% when each switch just makes contact.

FIGURE 3. TRACTION CARD SETTINGS ACCELERATOR POTENTIOMETER (See Figures 4 And 5) WARNING Disconnect the battery connector to prevent operation of the hydraulic system or electrical shock and possible injury.

The operator platform can move abruptly and cause an injury when any Lift or Lower buttons are accidentally pushed. Fully lower the operator platform.

Remove the key from the key switch and install a tag in the operator’s area stating “DO NOT OPERATE”.

NOTE: If the instrument panel is not opened for access to the accelerator potentiometer, do steps A and B.

4. If all of the checks of step 3 are correct, the accelerator potentiometer is good and correctly adjusted.

Connect the electrical connectors. If there were flat areas or infinity readings, the potentiometer must be replaced. See REPAIR in this section. If the resistance readings were smooth, but the values were not correct, adjust the potentiometer as described in step F of this procedure.

5. If the potentiometer does not need adjustment or replacement and no other parts will be checked, close and fasten the instrument panel and install the steering wheel or handle.

6. To adjust the potentiometer, see Figure 4 and do the following steps: a. Remove the three screws that fasten the handle assembly to the accelerator assembly. See Figure 4. Use wire or string to fasten the handle assembly out of the way without damaging the wires to the switches. b. Remove the “E” ring, shims and washer that fasten the round plate assembly to the shaft. Temporarily disconnect the electrical plugs for the direction/speed control.

1. Disconnect the battery so that the battery connector is completely free. Remove the steering wheel or handle. c. Connect an ohmmeter as in step 3. Temporarily remove the round plate assembly, spring and drive gear.

2. Remove the capscrews that fasten the top of the in- Loosen the setscrew that fastens the pinion gear to the strument panel to the cowl. Carefully tilt the instrument shaft of the potentiometer. Hold the potentiometer in the mount position. The setscrew normally holds the potenpanel for access to the accelerator assembly. tiometer in the mount position. Use a screwdriver to turn 3. Use an ohmmeter to check the resistance of the ac- the shaft of the potentiometer slightly without moving the celerator potentiometer. Check the resistance at the elec- pinion gear. Temporarily tighten the setscrew. Use your trical plug connector. Check between wire 13B and wire finger to rotate the pinion gear and check the two read28 at the connector. See Figure 4. Slowly move the di- ings as in step 3. The pinion gear must always be in the rection/speed control for forward travel and check for a neutral position after each check. Continue to repeat this step until the two readings are within 10%. resistance reading of 5K ohms

d. Carefully tighten the setscrew to 0.06 to 0.11 N.m (0.56 to 0.94 1bf in) torque without moving the pinion gear from the neutral position. Make sure that the setscrew is also tightened to hold the potentiometer so that the body cannot rotate.

drive gear on the shaft. The ends of the spring must be aligned with the stop pin of the accelerator assembly.

Install the washer, shims and “E” ring so that there is a clearance of 0.51 to 1.27 mm (0.020 to 0.050 in) between the washer and “E” ring.

e. Do step 6c.. to check that the adjustment is still cor- g. Install the handle assembly on the round plate assemrect. If necessary, do step 6c. and 6d. again until the bly. Make sure to install the handle assembly so that the checks in step 3 are correct after the setscrew is tight- operator has access to the switches. ened to the correct torque value. h. Connect the electrical connectors, close and fasten the instrument panel and install the steering wheel or f. Install the round plate assembly, spring and handle.

FIGURE 4. ACCELERATOR ASSEMBLY PARTS

FORWARD AND REVERSE SWITCHES NOTE: The only adjustment for the forward or reverse switch is the neutral position of the pinion gear. The position of the pinion gear is set during re-placement (see REPAIRS) or adjustment (see Accelerator Potentiometer) of the accelerator potentiometer.

LIMIT SWITCH LS-1 AND LS - 3 (TRACTION CUTOUT and TRACTION OVERRIDE) (See Figure 5)

Limit switch LS-1 (traction cutout) prevents trac-tion circuit operation when the operator platform is above 3810 mm (150 in). Optional limit switch LS-3 (traction override) enables the traction circuit again.

WARNING During the following check, the operator must move the lift truck and raise the operator platform. Make sure the operator does not move the lift truck or raise the operator platform to cause an injury.

FIGURE 5. UPRIGHT LIMIT SWITCH LOOSE CHAIN SWITCH (See Figure 6)

NOTE: If the lift truck has the optional traction override switch (LS-3), the operator can push the override button on the instrument panel to enable the traction cir- The loose chain switch is at the chain anchor near LS-2 on the upright side of the operator platform. See Figure cuit again.

6.

The best check of limit switches is an operational check.

If the traction circuit is disabled when the operator platform is above 3810 mm (150 in), the limit switch LS-1 is operating. Pushing the optional override switch LS-3 must enable the traction circuit again. If limit switch LS1 is not operating, adjust the limit switch. If the override switch does not operate, check the switch. If the switches check good, use the section DIAGRAMS, 8000 SRM 424 to check the circuits.

WARNING To adjust the loose chain switch, the operator platform must be raised to provide access. The lowering of the operator platform can cause an injury.

The operator platform must have a support or a chain to prevent the operator platform from lowering.

1. Raise the operator platform for access to the loose Adjust limit switch LS-1 so that the switch is closed chain switch. See Figure 6. Install beams as a support when the roller is on the bar of the upright and open for the operator platform or use chains to prevent the when the bar is above the roller. The roller must be cen- operator platform from lowering. The chains must be tered on the bar and the bar must be straight with no fastened to the operator platform and to a part of the upright that can not move. bends.

2. Disconnect the battery.

3. Adjust the nuts that fasten the switch bracket to the chain anchor. Adjust the nuts that fasten the switch to the switch bracket. Adjust these nuts for the clearances shown in Figure 6. The clearances must all be correct after the nuts are tight.

LIMIT SWITCH LS-2 (LOWERING SPEED, TRAVEL SPEED) Limit switch LS-2 limits the maximum lowering speed to the Slow Lower speed during the last 610 mm (24 in) of platform travel. Another part of the switch limits the maximum travel speed above 610 mm (24 in).

The best check of limit switch LS-2 is an operational check. Make sure the operator platform is at approximately one-half the maximum height. Lower the operator platform at the maximum speed. If limit switch LS-2 is operating, the lowering speed will decrease during the last 610 mm (24 in) of platform travel. Raise the operator platform above the 610 mm (24 in) height and operate the lift truck at maximum speed. As the lift truck is traveling at maximum speed, lower the operator platform. The lift truck speed must increase as the platform passes below the 610 mm (24 in) height. If limit switch LS-2 is not operating, adjust the limit switch or use the section DIAGRAMS, 8000 SRM 424 to check the circuit.

Adjust limit switch LS-2 so that the switch is closed when the roller is on the trip bar and open when the trip bar is not aligned with the switch roller. The roller must be centered on the bar and the bar must be straight with no bends.

NOTE: There is no adjustment for the override switch (limit switch LS-3) in the instrument panel.

FIGURE 6. LOOSE CHAINS SWITCH

REPAIR GENERAL

ment and tool damage can occur if the battery is NOT disconnected.

WARNING Do not operate a lift truck that needs adjustment or repairs. Report the need for adjustment or repairs immediately. If adjustment or repair is necessary, put a “DO NOT OPERATE” tag in the operator’s area. Remove the key from the key switch.

Disconnect the battery connector before making any inspections or repairs. Personal injury or equip-

Do not touch the terminals of capacitor Cl of the traction controller. The charge on the capacitor can cause electrical shock and personal injury. Use a screwdriver with an insulated handle or a jumper wire to make a short-circuit across the capacitor terminals. This action will discharge the capacitor to prevent electrical shocks.

REPLACE ELECTRICAL PARTS OF THE STEERING, HYDRAULIC OR OPTIONAL GUIDANCE SYSTEMS Replacement or repair of the electrical and mechanical parts of the steering system is in the section ELECTRIC POWER STEERING, 1600 SRM 418. Replacement or repair of the electrical and me-chanical parts of the hydraulic system is in the section HYDRAULIC SYSTEM, 1900 SRM 419. Replacement or repair of the contactor for the hydraulic pump motor is in the section EV-100 -Repair, 2200 SRM 288. Replacement or repair of the electrical and mechanical parts of the guidance system is in the section WIRE GUIDANCE — Repair, 2200 SRM 422.

REPLACE THE ACCELERATOR POTENTIOMETER (See Figure 4)

bly out of the way without damaging the wires to the switches.

4. Remove the “E” ring (9), shims and washer that fasten the round plate assembly (8) to the shaft. Remove the plate assembly, drive gear and spring from the shaft.

5. Install labels on the potentiometer wires for correct connection during installation. Use a soldering iron and pliers that have a long nose to remove the wires from the potentiometer terminals. Do not hold the soldering iron on a terminal too long. The wire can get too hot and damage the wire insulation.

6. Loosen the setscrew (15) in the pinion gear (5). Hold the pinion gear and slide the potentiometer shaft out of the gear and the assembly. Install the shaft of the replacement potentiometer in the assembly and pinion gear.

Do NOT tighten the setscrew.

WARNING

7. Use solder and a soldering iron to connect the wires The operator platform can move abruptly and cause to the potentiometer terminals. Do not hold the solderan injury when any Lift or Lower buttons are acci- ing iron on a terminal too long. The wire can get too hot dentally pushed. Fully lower the operator platform. and damage the insulation. Make sure to use enough Remove the key from the key switch and install a heat to make a good solder joint. tag in the operator’s area stating “DO NOT 0PERATE”.

8. Adjust the accelerator potentiometer as described in ADJUSTMENTS of this section.

Disconnect the battery connector to prevent operation of the hydraulic system or electrical shock 9. Close and fasten the instrument panel and install the and possible injury. steering wheel or handle.

NOTE: If the instrument panel is not opened for access to the accelerator potentiometer, do steps land 2.

REPLACE THE KEY AND OTHER CONSOLESWITCHES AND INDICATOR LIGHTS (See Figure 7)

1. Disconnect the battery so that the battery connector is completely free. Remove the steering wheel or handle. NOTE: See the following sections to replace other switches, indicators, gauges, meters or warning devices: 2. Remove the capscrews that fastens the top of the instrument panel to the cowl. Open the instrument panel ELECTRIC POWER STEERING, 1600 SRM 418. for access to the accelerator assembly.

ELECTRICAL GAUGES, METERS AND SENDERS, 2200 SRM 143.

NOTE: The numbers in the “()” of the following pro- ELECTRICAL WARNING DEVICES, 2200 SRM 144. cedure are the item numbers in Figure 4.

WIRE GUIDANCE REPAIR, 2200 SRM 422 .

3. Remove the three screws that fasten the handle as- BATTERY INDICATORS, 2260 SRM 138. sembly (2) to the accelerator assembly (3). See Figure 4. Use wire or string to fasten the handle assem-

FIGURE 7. CONSOLE SWITCHES AND INDICATORS WARNING The operator platform can move abruptly and cause an injury when any Lift or Lower buttons are accidentally pushed. Fully lower the operator plat-form.

Remove the key from the key switch and in-stall a tag in the operator’s area stating “DO NOT OPERATE”.

nal of the instrument panel indicator or switch to be replaced 4. Compress the clips that fasten the switch or indicator light to the instrument panel. Push the switch or indicator light out of the instrument panel. The key, Emergency Stop and optional override switches have a bezel nut that fastens the switch to the instrument panel. Remove the bezel nut and the switch.

Disconnect the battery connector to prevent operation of the hydraulic system or electrical shock 5. Make sure the picture symbol or words can be read and possible injury. by the operator. Install the switch, indicator or button using the reverse of the removal procedure.

NOTE: If the instrument panel is not opened for access to the accelerator potentiometer, do steps land 2.

6. Connect the wires as labeled during removal.

1. Disconnect the battery so that the battery connector 7. Close and fasten the instrument panel and install the is completely free. Remove the steering wheel or handle. steering wheel or handle.

2. Remove the capscrews that fastens the top of the REPLACE SWITCHES INTHE instrument panel to the cowl. Open the instrument panel DIRECTION/SPEED CONTROL for access to the accelerator assembly.

WARNING 3. Install labels on wires for correct connection during The operator platform can move abruptly and cause installation. Remove the wires from each termian injury when any Lift or Lower buttons are accidentally pushed. Fully lower the operator plat-form.

Remove the key from the key switch and in-stall a tag in the operator’s area stating “DO NOT OPERATE”.

Disconnect the battery connector to prevent operation of the hydraulic system or electrical shock and possible injury.

1. Disconnect the battery so that the battery connector is completely free.

2. Remove the three screws that fasten the handle assembly to the accelerator assembly. See Figure 4. Use wire or string to fasten the handle assembly out of the way without damaging the wires to the switches.

3. Install labels on the wires of the switch to be replaced so that the wires can be correctly connected during installation.

4. Compress the clips and push the switch out of the housing. Remove the bezel nut to remove the horn switch.

5. Make sure the picture symbol or words can be read by the operator. Install the switch, indicator or button using the reverse of the removal procedure.

FIGURE 8. FOOT SWITCH REPLACEMENT REPLACE LOOSE CHAIN SWITCH (See Figure 9)

The loose chain switch is at the chain anchor near LS-2 6. Install the handle assembly on the round plate as- on the upright side of the operator platform. See Figure sembly. Make sure to install the handle assembly so that 9. the operator has access to the switches.

REPLACE THE FOOT SWITCH (See Figure 8) 1. Remove the cover of the foot switch assembly.

2. Install labels on the wires of the switch so that the wires can be correctly connected during installation.

Remove the wires from the switch terminals.

WARNING To replace the loose chain switch, the operator platform must be raised to provide access. The lowering of the operator platform can cause an injury.

The operator platform must have a support or a chain to prevent the operator platform from lowering.

1. Raise the operator platform for access to the loose chain switch. See Figure 9. Install beams as a support 3. Remove the screws that fasten the switch in the housfor the operator platform or use chains to prevent the ing and remove the switch. operator platform from lowering. The chains must be fastened to the operator platform and to a part of the 4. Install the wires as labeled during removal. Install the upright that can not move. wires on the same terminals of the replacement switch and install the switch in the housing. Install the cover.

2. Disconnect the battery.

3. Install labels on the wires for correct connection during installation. Remove the wires from the switch terminals.

FIGURE 9. LOOSE CHAIN SWITCH

FIGURE 10. UPRIGHT LIMIT SWITCH

Upright Limit SwitchLS-1 4. Remove the nut that fastens the switch to the bracket (See Figure 10) and remove the switch.

Limit switch LS-1 is near the top of the upright. See Figure 10. Use a personnel lift platform for access to 5. Install the replacement switch on the bracket. Adlimit switch LS-1. just the nuts that fasten the switch to the switch bracket.

If necessary, adjust the nuts that fasten the switch bracket to the chain anchor. Adjust these nuts for the clearances WARNING shown in Figure 9. The clear-ances must all be correct after the nuts are tight The operator platform can move abruptly and cause an injury when any Lift or Lower buttons are acci6. Connect the wires to the switch terminals as marked dentally pushed. Fully lower the operator platform.

Remove the key from the key switch and install a during removal. tag in the operator’s area stating “DO NOT OPERATE”.

REPLACE THE LIMIT SWITCHES 1. Disconnect the battery.

Limit switch LS-1 is on the top of the upright. LS-2 is on the upright side of the operator platform near the loose chain switch. Limit switch LS-3 is on the instrument panel.

2. Remove the cover from the limit switch. Install la-bels on the wires for correct connection during installation.

Remove the wires from the switch terminals. Pull the wires out of the housing.

3. Hold the limit switch and remove the capscrews that 3. Hold the limit switch and remove the screws that fasfasten the limit switch to the bracket. ten the limit switch to the bracket.

4. Install the replacement limit switch on the bracket and push the wires through the hole at the bottom of the housing.

4. Install the replacement limit switch on the bracket and push the wires through the hole at the bottom of the housing.

5. Connect the wires to the switch terminals as marked during removal. Install the cover.

5. Connect the wires to the switch terminals as marked during removal. Install the cover.

Limit Switch LS-2 (Lowering Speed) (See Figure 11)

6. Adjust the switch as described in CHECKS AND ADJUSTMENTS.

WARNING To replace limit switch LS - 2, the operator platform must be raised to provide access. The lowering of the operator platform can cause an injury.

The operator platform must have a support or a chain to prevent the operator platform from lowering.

1. Raise the operator platform for access to the lowering speed limit switch LS-2. See Figure 11. Install beams as a support for the operator platform or use chains to prevent the operator platform from lowering.

The chains must be fastened to the operator platform and to a part of the upright that can not move.

2. Disconnect the battery. Remove the cover from the limit switch. Install labels on the wires for correct connection during installation. Remove the wires from the switch terminals. Pull the wires out of the housing.

FIGURE 11. REPLACE LIMIT SWITCH LS-2

INTRODUCTION GENERAL

DESCRIPTION (See Figure 1)

This section has the description for the parts of the frame. These parts include the frame weldment, doors, battery rollers, covers, the optional guide rollers and the R30EA-FS caster. The outer channel of the upright is part of the lift truck frame. The base arms are part of the weldment for the outer channel of the upright.

The frame has mounts for the following parts: (1) the upright assembly, (2) the steering system parts, (3) the electrical system parts, (4) the hydraulic system parts and (5) the doors, access panels and covers.

FIGURE 1. FRAME

1

REPAIR REMOVAL AND DISASSEMBLY (See Figure 1) There is very little repair required on the frame. Most repairs can be done by removing the neces-sary system parts. See the section for the system that has the part that must be removed.

To separate the frame weldment from the upright weldment, see the section VISTA UPRIGHT (Repair), (4000 SRM 384).

To replace the load wheels in the load arms, see the section PERIODIC MAINTENANCE, (8000 SRM 410).

Covers, Panels And Plates. (See Figure 1) The special plastic covers that protect the parts can be removed by removing the screws that fasten them.

There are two covers over the main frame weldment.

One cover is over the electrical compartment and lowering control valve. The other cover is

over the motor and hydraulic compartments. The panels at each end of the battery compartments can be removed by lifting the latch that fastens the panel.

R30EA-FS Caster And Caster Wheel (See Figures 1 and 2) Description The caster is one support for the rear of the lift truck and is under the hydraulic compartment. The drive wheel of the master drive unit is the other support for this end of the lift truck.

The axle of the caster is an articulated axle. The articulated axle permits both wheels of the caster to always have equal weight. Caster operation and wheel wear are better. The caster is fastened to the frame weldment by four capscrews and lockwashers. The complete caster can be replaced as a unit or the wheels can be replaced. Always replace the wheels as a set for better caster operation and wheel wear. A single new wheel of the set will wear rapidly.

FIGURE 2. CASTER WHEEL

2

REPLACING CASTER (See Figure 2) A. Put the rear of the lift truck on blocks. See HOW TO PUT THE LIFT TRUCK ON BLOCKS in the section PERIODIC MAINTENANCE, (8000 SRM 410.

B. Remove the four capscrews and lockwashers that fasten the plate of the caster to the frame weldment. Remove the caster.

C. Install the replaccmcnt caster using the capscrews and lockwashers. Tighten the capscrews to 68 N.m (50 lb ft) torque.

REPLACING CASTER WHEELS (See Figure 2) NOTE: Always replace the wheels as a set. Replacing only one wheel causes more wear on the new wheel. The caster also will not operate correctly causing more wear or caster damage.

A. Put the rear of the lift truck on blocks. See HOW TO PUT THE LIFT TRUCK ON BLOCKS in the section PERIODIC MAINTENANCE, (8000 SRM 410).

B. Remove The cotter pin, axle nut, lockwasher and guard washers at each caster wheel. Remove each caster wheel.

C. Completely fill new bearings with the grease shown in the MAINTENANCE SCHEDULE of the section PERIODIC MAINTENANCE, (8000 SRM 410). Install the bearings in the replacement wheels.

fire or electrical equipment that can make sparks. Follow the manufacture’s instructions and Cautions.

A. Remove all dirt from the surface to be painted. Clean the area to be painted. Use a solvent for painted surfaces. Do not use solvent on new paint. Make sure all oil and grease is removed.

B. Use sandpaper to remove the top surface of the paint and rust from the metal. All metal surfaces where the paint is completely removed, must be painted. Use a primer. Apply the primer before applying the final coat of paint.

C. Protect all surfaces that will not he painted.

CAUTION Do not paint the pads, plastic covers or knobs, ca-bles, decals and information plates or controls.

D. Paint the surfaces. Use the correct Hyster paint. Follow the directions on the container. See Figure 3 for the correct arrangement of the paint colors.

LABEL REPLACEMENT(See Figure 3) If the labels or information plates are missing or have damage, they must be replaced.

WARNING D. Install the guard washers at each bearing of each wheel.

Install each wheel, lockwasher and nut. Rotate each wheel as you tighten each nut. Tighten each nut. to remove all clearance. There will be a resistance to rotation of the wheel. Loosen the nut to the first alignment. to install the cotter pin. Install a new cotter pin at each nut.

PAINTING INSTRUCTIONS

WARNING Always use solvents and paints in an area with ventilation. Do not use s olvents or paints near heat,

If labels that have warnings or instructions are damaged, they must be replaced immediately.

NOTE: The nameplate is installed using rivets. The old rivets must be removed before installing a new nameplate or to change the nameplate information.

A. Make sure the surface is dry and has no oil or grease. Do not use solvent on new paint. Clean the surface of old paint using a cleaning solvent.

B. Remove the paper from the back of the label. Do not touch the adhesive surface.

C. Carefully hold the label in the correct position above the surface. Install the label in the correct position on the surface.

Make sure all air is removed from under the label and the corners and edges are tight.

3

FIGURE 3. COLOR ARRANGEMENT AND LABEL INSTALLATION

4

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INTRODUCTION DESCRIPTION Gear pumps have several sections and are made with a single set (single stage) of gears or with multiple sets (tandem) of gears. A single stage pump has two covers and the gear housing with the gears. Seals are used to prevent leaks between the sections. Tandem pumps have a gear housing for each set of gears. Most tandem pumps also have a center section for the bearings. The inlet and outlet ports are normally on the gear housing or rear cover. The front cover has the seal for the input shaft. The input shaft is connected to a driven sprocket, coupling, or gear by splines or a key.

All the gear pumps have devices that keep the thrust clearance at a minimum when the pressure increases.

When the pressure is low, the clearance increases to pre-

3

vent wear. To prevent leakage when the pressure is high, the oil from the outlet side of the pump is transferred to a wear plate. The oil pushes the wear plate against the gears. Some pumps have bearing blocks that move closer to the gears when the pressure increases.

OPERATION Gear pumps have the teeth of the gears engaged in the center of the pump. When the input shaft is turned, the drive gear turns the driven gear. The oil in the inlet chamber is moved out from the center by the teeth of rotating gears. The oil between the teeth is moved around the pumping chamber to the outlet chamber. The oil is pushed from the outlet chamber by the gear teeth that are beginning to engage.

4

1

2

2

4

1.

2.

3.

4.

ONE–SECTION PUMP DRIVE GEAR TWO–SECTION PUMP DRIVEN GEAR 8047

FIGURE 1. TYPES OF GEAR PUMPS

1

3

2

1

2

3

3

1

1. INLET 2. OUTLET 3. SEAL MADE BY GEAR TEETH

10055

10056

1. OIL ENTERS GROOVES IN BUSHINGS 2. OIL ENTERS INLET CHAMBER

FIGURE 2. OPERATION OF GEAR PUMP 2

FIGURE 3. CHECK VALVE 3

1 4 5

1.

2.

3.

4.

5.

INPUT SHAFT BEARING BLOCKS REAR COVER DRIVE GEAR CARTRIDGE, FLOW CONTROL AND RELIEF VALVE 6. DRIVEN GEAR 7. FRONT COVER

7 6 10047

FIGURE 4. BASIC PARTS OF A GEAR PUMP The gears and bearings are lubricated by oil from the outlet side of the pump. A small amount of oil flows past the gears and into the bearings and to the front seal cavity. A check ball and spring are installed in some pumps to keep pressure on the oil in this passage. The oil pres2

sure prevents air leaks through the front seal and makes sure there is oil to the bearings. When the pressure increases to the spring setting, the ball moves from its seat and oil flows to the inlet chamber.

Flow Control Valve

Relief Valve

Some of the pumps have a flow control valve in the rear cover. The flow control valve has either a piston and spring, or a cartridge with a piston and spring. The piston has an orifice that permits a constant volume of oil to flow to the controlled flow port. When the pump speed increases, the piston moves to partly open the passage to the main control valve. This action keeps constant the pressure difference across the orifice. A constant pressure difference between both sides of an orifice causes a constant flow through the orifice.

Some pumps have a relief valve installed in a cartridge or in a bore in the rear cover. Relief valves in the pump prevent the pressure in the controlled flow system from increasing beyond the specifications. The relief valve in the cartridge has a poppet and spring, with the seat for the poppet in the cartridge. The relief valve and flow control valve on some pumps are installed in the same cartridge. Some of the relief valves that are installed in the pumps are adjustable only with shims. Replace the cartridge if the relief valve has a problem.

1

32

2

3

31 4 29 28 27

5

6

30

1.

2.

3.

4.

5.

CAPSCREW WASHER REAR COVER DOWEL PIN SEAL

7

26

18

17 16

20

15 16.

17.

18.

19.

20.

21.

11

15

22 NOTE: There can be a variation of internal parts on different models of lift trucks.

BEARING BLOCKS DOWEL PIN SPACER O–RING CARTRIDGE RELIEF POPPET SPRING

9

14

21

25

8

GEAR HOUSING DRIVE GEAR SEAL SEAL SPACER SEAL RING FRONT COVER SHAFT SEAL BEARING BLOCKS DRIVEN GEAR

10

19

23 24

6.

7.

8.

9.

10.

11.

12.

13.

14.

22.

23.

24.

25.

26.

27.

28.

SPRING ADJUSTMENT SCREW O–RING PLUG SPRING FLOW CONTROL PISTON O–RING

13

12 10040

29.

30.

31.

32.

SNAP RING O–RING CAPSCREW AND WASHER CAPSCREW AND WASHER

FIGURE 5. HYDRAULIC GEAR PUMP, SINGLE–STAGE

3

5 1

2

3

6

4

1.

2.

3.

4.

7

5.

6.

7.

8.

11 12 10 9 8 2

3

15 10040

14

13

9.

10.

11.

12.

13.

14.

15.

16.

REAR COVER SEAL GLAND SEAL RETAINER WEAR PLATE, REAR DRIVEN GEAR DRIVE GEAR GEAR HOUSING WEAR PLATE, FRONT FRONT COVER STUD WASHER NUT SEAL SNAP RING SEAL PIN

NOTE: There can be a variation of internal parts on different models of lift trucks.

16

FIGURE 6. HYDRAULIC GEAR PUMP, SINGLE–STAGE

REPAIRS NOTE: Worn or damaged seals are the most common cause of pump repair. The pump bearings, gears and shafts also wear. Many service persons do not repair a worn pump because the cost of repairs can be greater than the cost of a new pump. The seals can be replaced in the hydraulic pump. If the pump will be rebuilt, the following general procedures are for repairing gear pumps.

REMOVAL

WARNING Make sure the carriage is lowered before disconnecting any parts of the hydraulic system.

1. If the lift truck is equipped with a valve on the tank, the valve must be closed before removing the pump. If there is no valve on the tank, remove the breather and install a plug. This action prevents the tank from draining too fast when the inlet line is disconnected.

2. On some electric lift trucks, the pump is installed inside of the hydraulic tank. Drain the tank and remove the cover on the side of the tank. See THE HYDRAULIC SYSTEM, E20–120B, 1900 SRM 161.

4

3. Disconnect the hoses from the pump. Put caps on all the fittings. Be careful so that the inlet hose is not damaged during removal.

4. If the pump is driven by a drive shaft, disconnect the drive shaft at the pump.

WARNING Some of the hydraulic pumps are very heavy. Use a lifting device when removing or installing the pump.

5. Remove the capscrews holding the pump housing to the mount.

6. Remove the pump from the lift truck.

DISASSEMBLY NOTE: See the illustration in the Figure that is similar the pump being repaired. The illustration can have parts that are different than those in the actual pump that is being repaired.

1. Remove the gear or sprocket from the input shaft.

2. Before disassembling the pump, make alignment marks on all the housings. Some of the housings can be assembled in the wrong positions, which will cause fail-

ure or increased wear. Carefully clean the outside of the pump.

bly. Some of the parts are similar, but not exactly the same and it can be difficult to make an identification if they are mixed.

NOTE: The inlet ports in most gear pumps are larger than the outlet ports.

3. Remove the capscrews or nuts that hold the housings together. Use a plastic hammer to separate the housings.

Do not damage the machined surfaces.

NOTE: If the pump is held in a vise for disassembly, make sure the vise does not hold the pump too tightly and cause distortion of the pump body.

4. Remove the gears and thrust plates (if used). Make a note of the positions of the thrust plates, seals and gaskets. Do not use a punch to mark the parts. Remove any springs and check valves.

NOTE: The position of the seals is important. In some pumps the direction of pump rotation is changed by changing the position of the seals and housings. The holes in the seals must be aligned with the oil passages in the housing sections. The oil passage for the thrust plates is in the outlet chamber.

5. Remove the bearings with a puller. In some pumps the bearing blocks or plates must be replaced with the bearings.

Make sure that you make careful notes of the location and orientation of the parts and seals during disassem-

1.

2.

3.

4.

5.

6.

7.

8.

9.

6. Remove the front seal.

SNAP RING NOTE: There can be a variation 12 BEARING of internal parts on different SEAL models of lift trucks.

FRONT COVER 11 PLUG RING SEAL ROLLER BEARINGS 10 SEALS THRUST PLATE 9 5

11

16

7 9

4

11 14

8

15 20

6 19

8 3

6

2 1

18

7

11 6

3332

7 9

9

17

13 6

7 8

10. DRIVE SHAFT AND GEARS 11. HOUSING SEAL 12. GEAR HOUSING

13. BODY 14. CONNECTOR SHAFT 15. GEAR SET

16.

17.

18.

19.

20.

GEAR HOUSING REAR COVER WASHER (4) STUD (4) NUT (4)

FIGURE 7. HYDRAULIC GEAR PUMP, TANDEM 5

1

2

3

7

4

8

10

9

11

12

3

8

9

6

13

6

10

5 1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

CAPSCREW (4) GEAR HOUSING PIN (4) DRIVE GEAR DRIVEN GEAR KEY (2) THRUST PLATE (2) GASKET, PLASTIC (2) GASKET, PAPER (2) SEAL (2) BODY GEAR HOUSING

3

3

15 16

14 6145

7

17 13. DRIVE GEAR AND SHAFT 14. DRIVEN GEAR AND SHAFT 15. SPRING

18

16. BALL 17. FRONT COVER 18. SEAL

FIGURE 8. HYDRAULIC GEAR PUMP, TANDEM

CLEANING Clean all parts of the pump with solvent. Use compressed air to dry the parts. Do not use a cloth to dry the parts. Pieces of the cloth can cause restrictions in the hydraulic system. Make sure the work area and tools are very clean.

NOTE: Some pump bodies will show gear marks where the gears rotate because of the small clearances between the parts. These gear marks do not indicate a worn or damaged pump unless the pump will not supply the volume and pressure shown in the specifications.

1. Inspect the outside edges of the gear teeth for grooves or scratches. If the edges of the gear teeth are sharp, use emery cloth to break the edges. Replace the gears if there are deep grooves on the gears.

3. Inspect the gear housing for wear or grooves. Most wear occurs on the inlet side of the gear chamber. Put a straight edge across the inlet side of the gear chamber. If a 0.13 mm (0.005 in) thickness gauge fits between the straight edge and the housing, the gear housing must be replaced. If the gear housing is worn, inspect the bearings for wear. If the system pressure is too high, the gear housings will wear quickly. Grooves in the gear chamber indicate dirt is in the oil. Small holes in the outlet side of the gear chamber indicate that cavitation has occurred. Make sure the inlet hose, fittings and tank have no restrictions. Cavitation can also occur when the engine speed is too high.

2. If the gear shafts have grooves or are worn more than 0.05 mm (0.002 in), they must be replaced. Wear on the seal area of the shaft indicates that there is dirt in the oil or a hard seal. Inspect the seal to see if it has been too hot.

Look for small cracks in the seal surfaces. If the seal was too hot or the wrong oil was used, the seal will be too hard or too soft. Inspect the splines or key groove for damage.

If the surfaces of the gear chamber or gear teeth have blue marks, the pump was too hot. Heat damage in the pump can be caused by hot oil or lack of oil. Check the front seal surface to see if air was entering the pump through the front seal. Make sure the oil is the correct viscosity. The wrong viscosity oil can increase leakage within the pump. Leakage inside the pump increases the oil temperature.

CAUTION Any dirt that enters the hydraulic system can cause damage to the parts.

INSPECTION

6

4. Check the thrust plates for wear or grooves. If the thrust plate is worn more than 0.05 mm (0.002 in), it must be replaced. Replace the thrust plate if it has grooves or holes. Dirty oil causes the thrust plate to wear near where the gears engage. Small holes on the outlet side the thrust plate are caused by cavitation. Lack of oil can also cause small holes in the thrust plates. If the color of the thrust plates has changed, the pump was too hot.

5. Inspect all the machined surfaces for scratches or damage. Remove with emery cloth any metal that is above the flat surface. Check the surfaces with a straight edge. Inspect the grooves for the seals for dirt or scratches.

6. Inspect the bearings for wear or damage. Replace the bearings if there is any small hole on the bearing surface.

Replace the bushing if it is not round.

7. Look for damage on the seals. Replace all the seals and O–rings, even if they are in good condition. Look for cuts or changes in shape that can cause damage. Find out what damage caused the pump to fail. A damaged seal for the thrust plate can cause the shaft seal to leak. A damaged shaft seal can cause air to enter the hydraulic system.

8. Inspect the flow control valve and relief valve for dirt or scratches. Make sure the piston moves freely in the bore. Look at the poppet and seat for damage. The springs must not be broken or bent. Inspect the O–rings for damage. Make sure the orifices are open.

9. If any parts of the pump have damage from dirt in the oil, inspect the hydraulic tank. Drain the tank, clean the screen and tank, and replace the filter.

CAUTION Do not permit dirty oil to enter the gear pump.

10. Inspect the inlet hose to the gear pump. Use a lamp to look inside the hose. Look for pieces of the rubber that are separating from the hose. Inspect the hose for restrictions at the bends. Check for loose fittings or damaged O–rings.

ASSEMBLY 1. Lubricate all parts with hydraulic oil before they are installed into the pump.

CAUTION Make sure no dirt enters the pump during assembly.

2. Put Loctite 290 sealant around the outside of the front seal. Install the seal in the front cover. Make sure the seal is installed straight. If the pump has a ball bearing for the shaft, install it in the front cover. Install the snap rings.

3. Install the needle bearings into the front and rear covers. Use a press to push the bearings into position. Push on the end of the bearings that has the writing. If the pump has check valves, install them in the cover.

4. Install the seals for the thrust plate. Install the rubber seal with the lips away from the gears. Install the paper gasket against the rubber seal. The plastic gasket is installed between the paper gasket and the thrust plate. Install the thrust plate with the bronze side toward the gears.

CAUTION Make sure the holes in the gaskets and seals are aligned with the hole in the output side of the pump.

The pump will not operate correctly if the oil from the outlet chamber cannot flow to the thrust plate.

Some pumps have thrust plates with small grooves for the seals. The seals must be cut to the correct length. Cut two strips that are 5.5 mm (0.22 in) long from the seal strip. Put grease on the seals and install them in the grooves in the center of the thrust plate. Cut the thrust plate on the front cover. Hit the thrust plate with a plastic hammer to 0.8 mm (0.031 in) from the machined surface. Cut four strips 6 mm (0.25 in) from the seal strip.

Push the strips into the slots in the thrust plate. Lightly hit the thrust plate against the machined surface. Use a sharp blade to cut the seals even with the edge of the thrust plate.

Install the seal that has a “W” shape and the spacer in the groove in the front cover. Do not bend the metal seal. Install the seal in the outer groove in the front cover. Install the bearing blocks in the same positions from which they were removed.

5. Install the gears and bearing blocks in the pump chamber housing. Make sure the gear housing is installed in the correct position. The small hole in some housings must be in the outlet chamber. The large channels in the inlet and outlet chambers must be toward the 7

rear cover. The arrow indicating the direction of rotation on the gear housing must be toward the front cover.

Align the marks on the gear housing with the marks on the covers.

6. Put the connecting shaft in the drive gear shaft on the pumps with two pump chambers. Install the thrust plates and seals. Put the gears and pump chamber housing on the center bearing housing with the marks aligned.

7

1 2 3

10

4 7 5 11

6 8 7 7

and flow control valve. Install the fittings with new O– rings.

INSTALLATION

CAUTION Before the gear pump is installed, loosen the lock nut on the adjustment screw for the relief valve. Loosen the adjustment screw until the spring is not compressed. If the relief valve was adjusted for a worn pump, the setting will not be correct for a new pump.

Damage to the hydraulic system can occur if the setting of the relief valve is too high.

Always install a new filter when repairs are made to the hydraulic system. Drain and replace the hydraulic oil if the oil is dirty or burned.

1. Install a new gasket or O–ring on the front cover of the pump. Put a thin layer of Never–Seez on the splines of the drive shaft. Fill the inlet port of the pump with hydraulic oil. Turn the drive shaft in the direction of rotation until oil comes out the outlet port.

2. Install the pump in the lift truck.

WARNING 12

9

10054

7 1. ADJUSTMENT SCREW 2. SPRING 3. SPRING 4. RELIEF POPPET 5. CARTRIDGE 6. SPRING 7. O–RING

8. PISTON, FLOW CONTROL 9. SNAP RING 10. RELIEF FLOW 11. CONTROLLED FLOW 12. MAIN FLOW

FIGURE 9. CARTRIDGE FOR THE FLOW CONTROL AND RELIEF VALVE

Some of the pumps are very heavy. Use a lifting device to help install the pump.

3. Install and tighten the capscrews. Remove the caps from the fittings. Connect the hoses.

4. Remove the plug from the breather on the tank. Install the breather. Open the valve on the tank. Fill the tank with clean hydraulic oil.

CAUTION Do not permit hot oil to enter a cold pump. Make sure the relief valve in each system is at the lowest setting.

7. Install the seal and rear cover. Use a plastic hammer to join the sections. Apply a small mount of Loctite 290 sealant to the threads of the capscrews or studs. Install the capscrews or studs and tighten with your fingers.

Rotate the drive shaft to make sure the pump is assembled correctly. Tighten the capscrews or nuts to the specification using an “X” sequence.

5. Install a 0 to 20 MPa (0 to 3000 psi) pressure gauge to a tee fitting at the pump outlet port. Start the engine and run it at idle speed for three minutes.

8. Use a soft blunt tool to install the O–rings in the bore of the flow and relief cartridge. Install the relief valve

6. Touch the pump with your hand. If the pump is hot, it has a problem. If the pump is not hot, then increase the

8

CAUTION Do not operate any valve until the pump has run for three minutes at low pressure and low speed.

engine speed to the high limit. Momentarily increase the pressure to the relief setting. Repeat this procedure for 3 minutes.

7. Look at the pressure gauge and adjust the relief valve.

See Checks And Adjustments for the lift truck for which you are making repairs.

CHECKS AND ADJUSTMENTS CHECK THE OUTPUT OF THE PUMP Two methods are given for checking the volume of flow from the hydraulic pump. The first method uses a flow meter, a pressure gauge, and a needle valve. The second method uses a needle valve, a pressure gauge, a container and a timer.

gauge on a tee fitting connected to a hose from the outlet port. Install the needle valve on the end of the hose. Connect another hose to the needle valve. Put the other end of the hose in a container with a 18 litre (5 gallon) capacity. Make sure the reservoir is full.

CAUTION

NOTE: If the pump has two outlet ports, do separate flow tests. Add the results of both tests to find the total output rate.

This test must be done quickly to prevent the hydraulic tank from becoming empty. Do not operate the engine when there is no oil in the hydraulic tank.

FIRST METHOD (See FIGURE 10.)

2. The needle valve must be fully open. Start the engine and run the engine at its governed rpm for 5 seconds.

Stop the engine. Measure the volume of oil that entered the container in 5 seconds. Multiply the quantity in the container by 12 to find the output per minute. Compare the pump output rate with the specifications found in the CAPACITIES AND SPECIFICATIONS section of the SERVICE MANUAL. The pump output rate must be within 20% of the specifications.

1. If the flow meter is available, install the flow meter between a needle valve and the outlet port of the pump.

The pressure gauge must be between the needle valve and the pump. Make a separate check for each system if the pump is a tandem or if a flow regulator is part of the pump. When the hydraulic oil is at operating temperature, run the engine at 2800 RPM with no load on the hydraulic system. Note the reading of the flow meter.

Compare the output rate of the pump with the specification found in the CAPACITIES AND SPECIFICATIONS section of the SERVICE MANUAL. 2. Run the engine at the high limit. Slowly close the needle valve until the gauge indicates a pressure just below the specification for the relief valve setting. The pump output at the high or pressure must be within 25% of the output with no load. If the output at high pressure is less than 75% of the low pressure output, the pump has a problem.

WARNING Hydraulic oil can be hot. Do not touch the oil during the tests.

SECOND METHOD (See FIGURE 11.)

1. Another method of checking the pump output is to measure the amount of oil moved in a given amount of time. Run the engine until the oil is 55 to 65°C (130 to 150°F). Disconnect the line from the outlet port of the pump. Install a 0 to 20 MPa (0 to 3000 psi) pressure

3. Start the engine and run the engine at its governed rpm. Close the needle valve until the pressure increases to just below the relief valve setting. measure the volume of fluid the pump moves in 5 seconds. Compare this quantity with the results from the test of the pump output at low pressure. The output of the pump at high pressure must be within 25% of the volume of oil flow at low pressure.

CHECK FOR AIR IN THE HYDRAULIC SYSTEM If the pump makes noise or does not move the correct amount of oil, check for air in the system. Run the engine until the oil is warm. Remove the filter head and look into the tank. If there are bubbles in the oil, air is in the hydraulic system. The most common place of entry of the air is in the inlet hose to the pump. Check for air leaks by pouring oil over the fittings and hose when the engine is running. If the noise decreases, the leak is in that area. See the Troubleshooting section for other causes of air in the hydraulic system.

9

4

1

1.

2.

3.

4.

5.

6.

7.

8.

2 5

HYDRAULIC PUMP INLET PORT OUTLET PORT HYDRAULIC TANK PRESSURE GAUGE TEE FITTING FLOW METER NEEDLE VALVE

7

8

10053

6 3

FIGURE 10. CHECK THE OUTPUT OF THE HYDRAULIC PUMP WITH A FLOW METER

4

1

2 9

5

7 3

1.

2.

3.

4.

5.

6.

7.

8.

9.

6

8

HYDRAULIC PUMP INLET PORT OUTLET PORT HYDRAULIC TANK PRESSURE GAUGE TEE FITTING NEEDLE VALVE CONTAINER TIMER 10052

FIGURE 11. CHECK THE OUTPUT OF THE HYDRAULIC PUMP 10

TROUBLESHOOTING PROBLEM

POSSIBLE CAUSE

The pump makes too much noise

Air in the hydraulic system The bearings or gears are damaged Outlet valve from the hydraulic tank is closed Low oil level in hydraulic tank Wrong oil Supply hose is twisted or has a restriction Breather on hydraulic tank has a restriction Seal for pump shaft is damaged Pump drive has a problem Relief valve is set wrong or is damaged Screen in hydraulic tank has a restriction Pump is loose or not installed correctly in its mount Engine speed too fast

Low hydraulic pressure

Relief valve is set wrong or is damaged Flow regulator valve is damaged Leak inside of a hydraulic cylinder Worn or damaged hydraulic pump Air in the hydraulic system Supply hose is twisted or has a restriction Low oil level in hydraulic tank Wrong oil Breather on hydraulic tank has a restriction Seal for pump shaft is damaged Pump drive has a problem Pump assembled wrong Screen in hydraulic tank has a restriction

Pump has leaks, loose fittings or damaged seals

Housing capscrews are loose Relief valve is damaged Pump housing is damaged Worn seals and pump shaft

11

TROUBLESHOOTING PROBLEM

POSSIBLE CAUSE

Pump is too hot Relief valve is set wrong or is damaged

Flow regulator valve is damaged Leak inside of a hydraulic cylinder Worn or damaged hydraulic pump Air in the hydraulic system Supply hose is twisted or has a restriction Low oil level in hydraulic tank Wrong oil Breather on hydraulic tank has a restriction Pump drive has a problem Pump assembled wrong Screen in hydraulic tank has a restriction Replacement hydraulic hoses are wrong size

Hydraulic pump wears faster than normal

Dirt in the hydraulic system Wrong hydraulic oil Relief valve is set wrong or is damaged Cavitation from restriction in inlet hose Pump drive has a problem Pump drive is not correctly aligned Pump is not installed correctly in its mount Pump is operating too hot Engine speed is too fast

Air in the hydraulic system

Low oil level in hydraulic tank Leak in inlet hose Loose inlet fitting Breather on hydraulic tank has a restriction Supply hose is twisted or has a restriction Screen in hydraulic tank has a restriction Pump seal is damaged Check valve in pump is damaged Pump housing capscrews are loose Worn or damaged hydraulic pump

12

13

INTRODUCTION This section describes the hydraulic system and has procedures for repair and adjustment. A guide for troubleshooting is included. See the section DC MOTOR REPAIR, 620 SRM 294, to repair the motor for the hydraulic pump. Repair procedures for the cylinders are in the section LIFT CYLINDERS, 4000 SRM 135. The section PERIODIC MAINTENANCE, 8000 SRM 410, has procedures for chang-ing the hydraulic oil and the filter.

DESCRIPTION Hydraulic System (See Figure 1) Power for the lift function comes from the hydraulic system.

The system has a plastic tank with an inter-

nal filter, a pump mounted on a DC motor, and a control valve.

When the pump motor is energized by a lift switch, oil flows from the tank through the pump to the control valve. Oil flows from the control valve to the lift cylinders in the upright. Solenoid valves in the control valve control the volume of oil that flows to or from the cylinders during lifting and lowering. The solenoid valves operate according to the selection of lifting and lowering speeds. The control valve has a relief valve to keep hydraulic pressure within the correct range.

The port in each lift cylinder has a lowering control valve. If a hydraulic line is damaged, these valves limit the flow of oil from the cylinders. This function controls the lowering speed of the platform.

FIGURE 1. HYDRAULIC SYSTEM

1

RELIEF VALVE

Pump (See Figure 1 and Figure 5)

The pump is a gear pump fastened to the end of the motor housing. A hydraulic hose and tube connect the pump outlet to the control valve. A coupling connects the motor shaft to the pump shaft. The motor shaft and the pump shaft each have a key that engages the coupling. The bushings at the sides of the gears inside the pump are the bearings for the gear shafts. The bushings have passages for the oil flow to the pump outlet and for lubrication. Special rings and seals prevent leaks between sections of the pump housing. An oil seal prevents leaks at the drive shaft.

The relief valve is an adjustable poppet valve. It opens when hydraulic pressure in the system reaches 17.2 MPa (2500 psi).

This function allows oil flowing from the pump to return to the tank. The relief valve protects the pump and other components of the system from too much pressure.

CHECK VALVE The check valve lets oil freely flow from the pump to the lift cylinders, but it prevents flow in the other direction. When the platform is raised and the pump is not operating, the check valve prevents oil from flowing through the pump to the tank.

MANUAL LOWERING VALVE Control Valve (See Figure 1 and Figure 2) The control valve is an assembly of cartridge valves and orifice plugs in a valve body. The cartridge valves can be replaced (see Repairs). The function of each cartridge valve is described below.

This valve is a needle valve that can be opened manually. The valve is used to lower the platform and upright if there is an electrical malfunction. When the valve is open, it lets oil flow from the lift cylinders to the tank. The knob on the valve can be used to control the rate of flow. An orifice plug keeps lowering speed at an acceptable rate when the valve is fully open.

FIGURE 2. HYDRAULIC SCHEMATIC

2

SOLENOID VALVE 1 (See Figure 3) This valve is a poppet-type valve actuated by a solenoid. The valve is normally closed. It is actuated (opened) by the switch for slow lifting and slow low-ering, and by the switch for fast lowering.

When the valve is open, oil can flow through it from the control valve passage between the pump and the lift cylinders.

When the operator selects SLOW LIFT, some of the oil goes through solenoid valve 1 and a flow regulator to the tank. When the operator selects SLOW LOWER, all of the oil from the cylinders returns to the tank through solenoid valve 1 and the flow regulator. During FAST LOWER, both solenoid valves let oil flow from the cylinders to the tank.

The oil passage from solenoid valve 1 has an orifice plug. It limits the flow from the valve.

SOLENOID VALVE 2 (See Figure 3) This valve is the same as solenoid valve 1. Solenoid valve 2 opens when the operator selects FAST LOWER. A limit switch (LS2) keeps solenoid valve 2 closed when the platform is lower than 610mm (24

in). This function keeps lowering speed slow when the platform is near the floor.

When solenoid valve 2 is open, oil can flow through it from the control valve passage between the check valve and the lift cylinders. During fast lowering, oil flows from the cylinders through both solenoid valves.

The oil passage from solenoid valve 2 has an orifice plug. It limits the flow from the valve.

FLOW REGULATOR This valve is a spool-type lowering control valve. By sensing differences in pressure, the valve gives a constant rate of flow through one or through both solenoid valves.

When oil flows through the solenoid valves, pressure decreases across the orifice plugs, which are restrictions. The spool in the flow regulator moves to keep the difference in pressure across the orifice plugs constant. This function gives a constant rate of flow through the solenoid valves for all load conditions.

3

FIGURE 3. SOLENOID VALVE OPERATION, LIFTING AND LOWERING 4

REPAIRS HYDRAULIC PUMP (See Figure 4 and Figure 5) NOTE: Seals that are worn or damaged are the most common cause of pump repair. The pump bearings, gears and shafts also wear. Most service persons do not repair a pump that is worn. The cost of repairs can be greater than the cost of a new pump. The special rings, seals and bushings in the hydraulic pump are replaceable. These parts come in the repair kit. The end covers also can be replaced. Replace the pump if other pump parts are damaged.

Removal The pump is fastened to the motor. The motor is fastened to the frame at the right-hand side of the front compartment. The hydraulic pump and motor can be removed as a unit. The pump can be removed separately.

NOTE: If the motor must be removed, do all the steps of this procedure. To remove the pump, do steps A, B, F and G. A. Disconnect the battery and open the front compartment doors. If the motor must be removed, put labels on the power cables and disconnect the power cables at the motor.

B. Loosen the hose clamp at the inlet and the hose fitting at the outlet of the pump. Oil can flow from the hoses when the hoses are disconnected. Have plugs ready to install in the hoses. Disconnect a hose and quickly install a plug in the hose. Disconnect the other hose using the same procedure. If the motor must be removed, install plugs on the fittings at the pump to prevent dirt from entering the pump.

C. Remove the M8 capscrews, washers, and spacers that fasten the bottom of the motor to the bracket. See the mount detail of Figure 4.

FIGURE 4. PUMP AND MOTOR

5

D. Make a mark on the top of the motor housing for correct alignment of the motor during installation. Hold the motor assembly to keep it from falling and remove the other M8 capscrews, washers, and spacers that fasten the motor.

E. Use a sling around the pump motor and a crane to lift the motor and the pump. The crane and sling must have a lifting capacity of approximately 45 kg (100 lb). Do not damage the motor terminals or pump fittings.

F. Remove the hydraulic fittings from the pump. Loosen the setscrew in the coupling for the pump shaft key. Remove the two capscrews and lock washers that fasten the pump to the motor. Slowly remove the pump from the motor and coupling.

Keep the shaft key for installation.

G. If the coupling (or the motor) must be replaced, loosen the other setscrew and remove the coupling

from the motor shaft. Keep the shaft key for installation.

Seal Replacement CAUTION If the pump is held in a vise for disassembly, use soft jaws in the vise. Make sure the vise does not hold the pump too tightly and cause distortion of the pump housing.

Make notes of the locations of the parts and seals during disassembly. There are two types of special rings. Make a note of the location of each type.

A. Carefully remove the end covers. Make a note of the special ring and seal arrangement. Do not disassemble the gear and bushing assembly.

B. Carefully remove the bushing seals from the bushings and pump housing.

FIGURE 5. HYDRAULIC PUMP

6

C. Inspect the pump gear assembly and the pump housing for wear and damage. Replace a damaged or worn hydraulic pump.

D. If necessary, clean the hydraulic hoses. Connect the hoses to the inlet and the outlet fittings on the pump.

NOTE: Some pump housings will show gear marks. These marks are caused by the small clearances between the parts.

Gear marks do not indicate a worn or damaged pump unless the pump does not operte according to the specifications.

E. Connect the power cables to the motor terminals according to the labels.

D. If necessary, clean the internal parts of the hydraulic pump.

Lubricate the parts with clean hydraulic oil as the pump is assembled.

E. Install the gear and bushing assembly in the pump housing.

Make sure each bushing is correctly aligned.

F. Install new bushing seals and special rings. Install new housing seals. See Figure 5 for the correct arrangement. Install the end covers and the special washers and capscrews. Tighten the capscrews to 46 N.m (34 Ibf ft).

G. Install a new oil seal on the shaft. Carefully press the oil seal into the end housing. Install a new snap ring.

F. Check the level of the hydraulic oil. See Maintenance Procedures in the section PERIODIC MAINTENANCE, 8000 SRM 410.

CONTROL VALVE Service the control valve by replacing the seals on a cartridge valve that leaks, or by replacing a defective cartridge valve.

See Figure 6.

Removal NOTE: Most of the cartridge valves can be removed without removing the control valve from the lift truck. For this procedure, do steps B and C first, but do not remove the battery.

Then, see Disassembly.

Installation A. If necessary, install the coupling on the motor shaft. See Figure 4. Install the key in the motor shaft before the coupling is installed. Tighten the setscrew in the coupling. Install the key in the pump shaft. Carefully install the pump shaft in the coupling while installing the pump on the motor. Install the lock washers and capscrews. Tighten the capscrews to 20 N.m (15 lbf ft). Tighten the setscrew in the coupling.

B. If the motor was removed, use the M8 capscrews, washers, and spacers to install the pump and motor on the brackets.

Replace damaged bushings. See the mount detail in Figure 4.

C. Clean the fittings and install the fittings on the pump. The pump must have oil for first operation. Before connecting the hydraulic hoses, fill the pump with clean oil at the outlet fitting.

WARNING Before servicing the control valve, fully lower the platform, turn the key switch to OFF, and disconnect the battery.

Failure to do this can cause an accident.

A. Remove the battery. See Battery Removal in the section PERIODIC MAINTENANCE, 8000 SRM 410.

B. Remove the capscrews and open the compartment doors.

Remove the cover of the electrical compartment above the battery for access to the control valve.

WARNING Do not touch the terminals of capacitor C1 on the traction control. The charge on the capacitor can cause electrical shock and personal injury. To discharge the capacitor and prevent a shock, use an insulated screwdriver or jumper wire to make a short-circuit across the capacitor terminals.

7

FIGURE 6. CONTORL VALVE CARTRIDGES C. Figure 7 has the wire diagram for the solenoid valves. If necessary, put labels on the wires for correct installation. Disconnect the wires at the terminals on the coils.

D. Remove the tube from the fitting on the inlet in the top of the control valve. See Figure 1. Put a plug on the tube.

E. Loosen the clamp and remove the hose from the fitting in the outlet of the valve. See Figure 1. Put a plug in the hose and keep the end of the hose above the level of the sight glass in the hydraulic tank.

8

F. Disconnect the hose for the lift cylinders at the control valve.

See Figure 1. Put a plug in the hose.

G. The bolts that fasten the control valve are in slots in the frame. Make a mark on the frame for the position of the control valve. Use the mark to make sure the handle of the manual lowering valve is aligned with the hole in the cover during installa-tion.

H. Remove the bolt that fastens the bracket for the diode block to the control valve. Do not let the nut and the washer fall into the battery compartment.

Carefully move the diode block and wires away from the valve.

I. Remove the other bolt from the control valve and recover the nut and the washer.

B. Carefully remove the other cartridge valves from the control valve, as necessary. Keep the parts clean.

C. Remove the fittings and outer plugs as necessary for cleaning and inspecting the valve body.

J. Remove the control valve from the lift truck.

CAUTION Do not remove orifice plugs from the cavities inside the control valve. The parts are easily damaged.

Cleaning and Inspection

WARNING Cleaning solvents can be flammable and toxic, and can cause skin irritation. When using cleaning sol-vents, always follow the solvent manufacturer’s recommended safety precautions.

FIGURE 7. WIRE DIAGDRAM, SOLENOID VALVES Disassembly NOTE: Only disassemble the control valve as neces-sary for repairs. Do not disassemble the cartridge valves. Replace a cartridge valve that has a fault.

WARNING Compressed air can move particles so that they cause injury to the user or to other personnel. Make sure that the compressed air path is away from all personnel. Wear protective goggles or a face shield to prevent eye injuries.

Carefully remove the seals and clean the cartridge valves with solvent. Clean other parts as necessary. Dry the parts with compressed air.

Inspect each cartridge valve for dirt and defects. Replace defective cartridge valves.

CAUTION Clean the outside of the control valve before disassembly.

Dirt can damage valves and prevent operation.

A. Remove the solenoid valves. See Figure 6.

1. Remove the coil nuts (13).

Inspect the body of the control valve. Carefully in-spect each cavity. Make sure the cavities do not have burrs, metal particles, or dirt. If the body has a defect, or damage, replace the control valve as an assembly.

Assembly

A. If fittings and outer plugs were removed, install the fittings and plugs. Use new O-rings.

2. Remove the coils (14) from the solenoid valves (12).

B. Lubricate each cartridge valve with clean hydrau-lic oil and install new O-rings and back-up rings. See Figure 6. Only use seals from approved kits.

3. Carefully remove the solenoid valve cartridges from the control valve. Keep the cartridges and the bores clean.

C. Carefully install each cartridge valve in its cavity in the control valve. Make sure the cartridge and

9

cavity are correctly matched. Turn each cartridge valve by hand up to the top O-ring. If a cartridge valve does not turn easily, the cavity is wrong and the control valve body must not be used.

D. Tighten each cartridge valve to the correct torque. See Specifications.

NOTE: 24-volt and 36-volt lift trucks have differ-ent solenoid valve coils. Every coil has a voltage la-bel. Only install coils that match the voltage of the electrical system in the lift truck.

E. Install the coils on the solenoid valves. Tighten the coil nuts to 2.3-2.8 N.m (20-25 1bf in).

Installation A. Put the control valve in the electrical compartment. Align the valve with the mark on the frame. Install the left bolt through the valve and the frame.

B. Put the diode block and bracket on the control valve. Install the right bolt through the bracket, valve, and frame.

C. Install the washers and nuts on the bolts. Tighten the nuts to 11 N.m (8 1bf ft).

D. Connect the hose for the lift cylinders to the fitting on the control valve. See Figure 1.

E. Use a hose clamp to connect the return hose to the fitting in the outlet of the control valve. See Figure 1.

F. Connect the tube to the fitting in the inlet on the top of the control valve. See Figure 1.

G. Correctly connect the wires to the terminals on the solenoid valves. See Figure 7.

H. Install and connect the battery. See the section PERIODIC MAINTENANCE, 8000 SRM 410, for the correct procedure.

Operate the hydraulic sys-tem and use all lifting and lowering speeds. Check for leaks and for correct operation of the solenoid valves. See Description for the functions of the solenoid valves. If necessary, adjust the relief valve according to the procedures in Checks and Adjustments.

I. Install the cover of the electrical compartment and fasten the doors.

CHECKS AND ADJUSTMENTS RELIEF VALVE ADJUSTMENT CAUTION The temperature of the hydraulic oil must be 54-66° C (130150° F) when the relief valve is adjusted. If the oil is too cold or too hot, the setting will be wrong.

A. Fully lower the platform. Disconnect the battery. Open the doors of the front compartment.

B. Disconnect the hose at the fitting in the outlet of the pump.

See Figure 1.

C. Install a tee fitting between the outlet fitting on the pump and the hose. Connect a pressure gauge (20 MPa [3000 psi]) to the tee fitting.

10

D. Make sure there is clearance above the upright. Connect the battery. Get assistance from a qualified operator to raise the platform.

WARNING Do not operate the foot switch while raising or lowering the platform. The lift truck can move if the control handle is rotated while the foot switch is pushed down. To avoid an accident, only use the lifting and lowering switches on the control handle.

E. When the platform is fully raised, push the FAST LIFT button and hold the button. Check the pressure on the gauge while the pump runs. The correct maximum pressure is 17.2 MPa (2500 psi).

CAUTION When you check relief pressure or adjust the relief valve, do not operate the pump at relief pressure for more than ten seconds. The temperature of the pump motor can increase rapidly, and too much heat can damage the motor.

Let the motor cool between checks.

F. If the pressure is greater then 17.2 MPa (2500 psi), or less than 16.5 MPa (2400 psi), adjust the relief valve. See Figure 6.

1. Remove the plug (5) from the relief valve (1).

2. Put a wrench into the adjusting screw (7).

3. Push and hold the FAST LIFT button.

4. Adjust the screw for a pressure of 16.5 to 17.2 MPa (2400 to 2500 psi). If the pump does not develop the lower pressure, see Troubleshooting.

G. When the checks are complete, install the plug in the relief valve, lower the platform, and disconnect the battery. Remove the gauge and the tee fitting. Connect the hose to the pump.

Connect the battery, operate the lift system, and check for leaks.

TROUBLESHOOTING HYDRAULIC PUMP

11

HYDRAULIC PUMP (Continued)

CONTROL VALVE

12

SPECIFICATIONS

13

INTRODUCTION GENERAL 2

2

1

3

This section describes how to select and do the maintenance for large batteries used in electric lift trucks. This information is for service personnel that must do the maintenance on large lead–acid batteries. Battery repair requires special training and equipment. Do not try to repair a battery unless you have the correct tools,equipment and experience. Most battery repairs are done by a special repair service.

4 5

6

LEAD–ACID BATTERIES A lead–acid battery converts chemical energy into electrical energy. Chemical changes within the battery gives the electrical energy. When the chemical reaction has occurred so that the battery will not give its rated voltage and current, the battery is discharged. A reverse chemical action must occur so that the battery can be used again. The batteries described in this section can be charged again by an electric voltage and current from an outside source so that there is a reverse chemical action.

The lead–acid chemicals store the electric energy until the electric energy is needed to operate an electric device.

7 7

8 9

12751

10

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

VENT AND FILL CAP POST POST SEAL PLATE PROTECTOR (SHIELD) POSITIVE PLATE EXPANSION MATS RETAINER SEPARATOR NEGATIVE PLATE BATTERY JAR

FIGURE 2. THE BATTERY CELL A lead–acid battery is made from several lead–acid batteries called cells. Each cell has positive and negative plates with dielectric spacers between each plate. All of the plates are within a solution of electrolyte. See FIGURE 2.

SPECIFIC GRAVITY 6193

FIGURE 1. LEAD–ACID INDUSTRIAL BATTERY

The strength of the electrolyte is measured in points of specific gravity. For example, a solution of sulfuric acid has a specific gravity of 1.835. Water has a specific 1

gravity of 1.000. Electrolyte is 27% acid and 73% water and has a specific gravity of 1.275.

removed from the electrolyte, the specific gravity of the electrolyte decreases. See FIGURE 5. The potential difference of a discharged cell is approximately 1.75 volts.

CAUTION NEVER pour water into concentrated acid. The quick generation of heat can cause the acid to boil and splash out of the container. ALWAYS pour concentrated acid into water when making a dilute solution of acid.

THE CHEMICAL REACTION IN A CELL In a fully charged cell, the electrolyte has a specific gravity of 1.270 to 1.130. NEVER discharge a battery below a specific gravity of 1.130. The battery can have permanent damage if discharged below 1.130.

–

2.06 VOLTS

–

ÍÍÍÍ ÍÍÍÍ ÍÍÍÍ ÍÍÍÍ ÍÍÍÍ ÍÍÍÍ ÍÍÍÍ

DECREASED SULPHURIC ACID INCREASED WATER

DECREASED SPONGE LEAD

+

+

LESS THAN 2.06 VOLTS

ÂÂÂ ÇÇÇ ÇÇÇ ÂÂÂ ÇÇÇ ÂÂÂ ÇÇÇ ÂÂÂ ÇÇÇ ÂÂÂ ÇÇÇ ÂÂÂ ÇÇÇ ÂÂÂ

DECREASED LEAD PEROXIDE

INCREASING LEAD SULPHATE

ÂÂÂÂ ÂÂÂÂ ÂÂÂÂ ÂÂÂÂ ÂÂÂÂ ÂÂÂÂ ÂÂÂÂ

6194

FIGURE 4. CELL IS DISCHARGING

ELECTROLYTE

NEGATIVE PLATE SPONGE LEAD

POSITIVE PLATE

LEAD PEROXIDE 6195

FIGURE 3. FULLY CHARGED CELL The cell generates a voltage (potential difference) when two different types of metal are in the electrolyte. The two metals in a lead–acid cell are lead peroxide (PbO3) for positive plates, and sponge lead (Pb) for negative plates. See FIGURE 3. A potential difference of approximately two volts per cell is generated. The potential difference does not vary according to the size of the cell.

During the discharge of the cell, lead peroxide and sponge lead mix with sulfuric acid to make lead sulfate (PbSO4) on both plates. See FIGURE 4. This action decreases the voltage in the cell. When the sulfuric acid is 2

1.75 VOLTS

–

ÍÍÍÍ ÍÍÍÍ ÍÍÍÍ ÍÍÍÍ ÍÍÍÍ ÍÍÍÍ ÍÍÍÍ MINIMUM SPONGE LEAD

MINIMUM OF SULPHURIC ACID MAXIMUM WATER

+

ÂÂ ÇÇÇ ÇÇÇ ÂÂ ÇÇÇ ÂÂ ÇÇÇ ÂÂ ÇÇÇ ÂÂ ÇÇÇ ÂÂ ÇÇÇ ÂÂ

MINIMUM LEAD PEROXIDE

MAXIMUM LEAD SULPHATE 6193

FIGURE 5. DISCHARGED CELL When a direct current is applied to a discharged cell, the lead sulfate is changed into lead and sulfuric acid. The lead goes to the positive plate and stays as lead and to the negative plate and stays as lead peroxide. See FIGURE 6. The concentration of sulfuric acid in the

electrolyte increases. The specific gravity of the electrolyte increases as the concentration of sulfuric acid increases. In a fully charged cell, the positive plate again contains the lead peroxide and the negative plate contains the sponge lead.

Alternating Current (AC). When the polarity of voltage between two terminals is changing between positive and negative at a quick and constant rate, the voltage is called Alternating Current.

HOW TO SELECT THE BATTERY BATTERY CHARGER

–

2.33 VOLTS

ÍÍÍ ÍÍÍ ÍÍÍ ÍÍÍ ÍÍÍ ÍÍÍ ÍÍÍ

INCREASED SULPHURIC ACID DECREASED WATER

INCREASED SPONGE LEAD

The battery needed to operate a period of eight hours depends on many conditions. Operations that require the lift truck to go up ramps or require the use of additional attachments increases the use of power from the battery.

Some work conditions require that more than one battery must be used during a work period. The number of eight hour work periods per day is normally equal to the number of batteries needed. For example, for three work periods you need three batteries. The capacity of the battery you need is found as follows:

+

ÂÂÂ ÇÇÇ ÇÇÇ ÂÂÂ ÇÇÇ ÂÂÂ ÇÇÇ ÂÂÂ ÇÇÇ ÂÂÂ ÇÇÇ ÂÂÂ ÇÇÇ ÂÂÂ

INCREASED LEAD PEROXIDE

DECREASED LEAD SUPLHATE 6192

FIGURE 6. CELL IS CHARGING

ELECTRICAL TERMS Voltage is an electromotive force (EMF) (also called “potential difference”) caused by the difference in electric charge between two points.

Ampere is a measurement of electric current.

Watt is a measure of electric power. The number of watts is equal to the number of volts multiplied by the number of amperes. A kilowatt–hour is 1000 watts of electric power used in one hour.

Ohms is the measurement of electrical resistance.

Polarity. In a battery, the electric current is shown to flow from the positive terminal to the negative terminal.

Direct Current (DC). When the voltage between the two terminals is always the same polarity, the current flow and voltage is called Direct Current.

•

The size of the lift truck and the attachments.

•

The type of work. Heavy duty operation or normal operation for one eight hour work period.

Lift trucks are available in various voltage ranges. The small ”WALKIE” lift trucks are normally 12 or 24 volts.

The larger sit–down rider lift trucks are normally 24, 36, 48, 72, or 80 volts. The number of cells in a lead–acid battery gives the battery voltage. A fully charged cell has a potential difference of approximately two volts.

This potential difference does not change with size of the cell.

VOLTAGE OF A BATTERY The battery voltage you need is found as follows: •

Will your lift truck operate on more than one voltage?

•

If you have more than one lift truck in operation, do the battery voltages need to be the same?

To reach the necessary battery voltage, the cells are connected in series. For example: 24 volts = 12 cell battery 36 volts = 18 cell battery 48 volts = 24 cell battery 72 volts = 36 cell battery 80 volts = 40 cell battery 3

X

VOLTS A VOLT IS THE MEASUREMENT OF ELECTROMOTIVE FORCE.

AMPS

= WATTS

AN AMPERE IS A MEASUREMENT OF CURRENT FLOW.

A WATT IS THE MEASURE OF ELECTRIC POWER.

OHMS AN OHM IS THE MEASURE OF ELECTRICAL RESISTANCE.

DC CURRENT FLOWS ONLY IN ONE DIRECTION.

AC CURRENT CHANGES DIRECTION OF FLOW. 6177

FIGURE 7. ELECTRICAL TERMS

6191

FIGURE 9. MULTI–CELL BATTERY FOR ELECTRIC LIFT TRUCK

BATTERY RATINGS FIGURE 8. CELL VOLTAGE

THE BATTERY AS A COUNTERWEIGHT On electric lift trucks that use the battery as part of the counterweight, the battery is part of the capacity of the lift truck to lift loads. The minimum weight of the battery is shown on the nameplate. If the battery is not the minimum weight, the capacity of the lift truck is reduced. If the battery used in the lift truck is less than the size of the battery compartment, blocks and spacers must be installed to hold the battery in position.

4

The ratings of batteries are measured in ampere–hours and kilowatt–hours at a constant rate of discharge. A rating of six hours is the standard. Ampere–hours is the measurement of battery capacity. To calculate ampere– hours, multiply amperes by hours. For example, 5 amperes times 5 hours is 25 ampere–hours. You cannot change the potential difference of a cell. You can increase the ampere–hour rating by increasing the number of plates in a cell, or by installation of larger plates. The constant rate of discharging can be compared to a measurement of the battery capacity and ampere–hours. For example, a battery with a rating of 600 ampere –hours during a work period of six hours will generate 100 am-

peres per hour for six hours. The same battery can not generate 300 amperes for two hours. The heat generated within the battery will damage the battery.

Kilowatt–Hours A kilowatt is 1000 watts. A watt is a measure of electric power. The capacity in kilowatt–hours is the total power generated by the battery. Watt–hours are measured by multiplying the voltage by ampere–hours. To measure the kilowatt–hours, divide the watt–hours by 1000.

Volts x amperes x hours 1000

= kilowatt–hours or KWH

To calculate the kilowatt–hours for a battery that has a rating of 600 ampere–hours and a 48 volt system, use this formula: 48 volts x 600 ampere–hours = 28.8 KWH 1000

Read the battery selection book available from your dealer for HYSTER lift trucks. This book shows the watt–hours in electric energy needed for various operations. A description of the operation includes distances, loads, ramps, lifting heights, attachments, etc. The watt–hours can be converted to kilowatt–hours to indicate the battery needed for the operation. Always select the correct type of battery. Remember, a battery that has a rating of 300 ampere–hours will not do the same job as a battery that has a rating of 600 ampere–hours. Do not permit the specific gravity to go below the limits shown in the manual.

AMPERES x HOURS = AMPERE–HOURS 600 AMPERE–HOURS = 100 AMPERES FOR SIX HOURS VOLTS x AMPERES x HOURS/1000 = KILOWATT–HOURS (KWH)

FIGURE 10. BATTERY CAPACITY TERMS

BATTERY MAINTENANCE Battery maintenance must include the following items: • a good battery charger • a clean battery • keep the electrolyte at the correct level • and keeping a record of the battery.

SAFETY PROCEDURES 1. Wear a rubber apron, gloves, boots, and goggles or a face shield when doing maintenance on batteries.

2. Batteries generate hydrogen gas when they are being charged. Keeps open fire away from batteries. Do not check the electrolyte level with a match or a lighter. No smoking and do not create sparks.

3. Lift batteries correctly with a crane or equipment designed for the job. Always use a spreader bar designed and and adjusted for the battery. Move batteries with a lift truck or a conveyor or rollers designed for that purpose. If the battery does not have a cover, a rubber mat or

6196

FIGURE 11. BATTERY INSPECTION REPORT 5

6197

FIGURE 12. BATTERY INSPECTION REPORT insulating material must be put over the top of the battery to prevent a short–circuit with other equipment.

Make the the lifting equipment has enough capacity for the job. Do not use chain or wire rope slings.

4. Never put metal materials or tools on a battery.

5. Disconnect the battery from the lift truck before doing maintenance or repairs.

6. When maintenance on the battery or the battery charger is required, disconnect both the AC and DC power. If the battery connectors must be replaced, make sure the positive and negative terminals and cables are kept separate and insulated from each other. Even a momentary short–circuit can cause an explosion and damage the battery.

7. Keep water readily available to flush spilled electrolyte. Electrolyte in the eyes must be flushed with water immediately and then quickly get medical attention.

Special showers and eye wash systems are required in areas where battery maintenance is done.

8. If electrolyte is spilled on a work surface or the floor, flush the area with water, use a solution of soda (sodium bicarbonate) to make the acid neutral.

6

9. Only trained persons are permitted to do maintenance on batteries and battery chargers. Make sure that the regulations by government safety agencies, government insurers, private insurers, and private organizations are followed when doing maintenance on batteries.

MAINTENANCE RECORDS NOTE: Follow the same sequence when you record the cell number. Always begin the record with a positive cell. Follow a sequence so that the last cell is always the cell for the negative cable.

Record the beginning ampere reading of the charger each time the battery is charged. Any difference in the daily ampere reading can indicate a problem with the battery or the charger.

THE NEW BATTERY Inspect a new battery for damage. Make sure the electrolyte in each of the cells is at the correct level. Charge the battery for six hours or until the specific gravity is correct. Make sure the battery is correctly installed in the lift truck. Use a spreader bar with slings designed for the battery to lift and move the battery. See FIGURE 13.

HOW TO CLEAN THE BATTERY Keep the battery compartment clean and dry. Use a clean cloth to wash the battery with water. Dry with compressed air.

CAUTION Do not clean the battery with steam or hot water. Do not use a high–pressure hose.

11449

INSULATED SPREADER BAR

INSULATED STRAPS

Remove any electrolyte from the battery compartment to prevent corrosion. If there is electrolyte on the top of the battery, apply a solution of bicarbonate of soda. Mix a solution containing 0.5 kg of soda for every 4 litres of water. Apply the solution, then flush the solution from the battery with clean water. Wash the battery and battery compartment as needed, but within a six month period as the maximum time.

NOTE: If the top of the battery is wet from electrolyte, check that the electrolyte level is too high or the battery charger is not operating correctly.

HOW TO ADD WATER

6190

FIGURE 13. CHANGE THE BATTERY

CAUTION Always use a spreader bar and slings that lift vertically on the lifting eyes of the battery. DO NOT use a chain or sling without a spreader bar or you will damage the battery case.

Use the correct blocks or spacers to hold the battery in position in the lift truck. Make sure that the battery compartment is clean and dry. All of the vent caps must be in position when the battery is in service. If the vent caps are not installed, the electrolyte will leak, causing corrosion on the battery case and in the battery compartment.

Always complete the Battery Inspection Report and the Daily Battery Report. See FIGURE 11. and FIGURE 12.

NOTE: Some batteries have sealed cells. These batteries do not need water added to the electrolyte.

Some water is lost from the electrolyte of each cell during the charge and discharge cycle when the battery is in service. Check the electrolyte level daily. Some service persons check some of the cells each day so that all of the cells are checked each week. If the level of the electrolyte goes below the level of the top of the separators for the plates, the cell can be damaged.

KEEPING THE ELECTROLYTE LEVEL WITHIN THE CORRECT LIMITS IS THE MOST IMPORTANT ITEM OF BATTERY MAINTENANCE. See the instructions from the manufacturer of your battery for the operating level of the electrolyte. Always use distilled water. If you add distilled water, wait five minutes before measuring the specific gravity with a hydrometer. DO NOT add water to a cell before or during the charging cycle; water must be added after the charging cycle. If water is added before the charging cycle, the electrolyte level may rise which will cause electrolyte to be forced out of the vent plugs. The electrolyte can flow out of the cell through the fill hole. The correct electrolyte level is shown in FIGURE 14.

7

3

2

1

4

the electrolyte level decreases by 3 mm (1/8 in), the specific gravity measurement can increase by 3 to 5 points.

When you use the hydrometer, make sure there is enough liquid in the barrel to let the float move freely.

The float must not touch the side, top, or bottom of the barrel. See FIGURE 15. for the correct method of reading the hydrometer.

5

BATTERY TEMPERATURE 1.

2.

3.

4.

5.

6.

7.

6 7 6188 FILL TUBE BOTTOM OF FILL TUBE CELL COVER MAXIMUM LEVEL OF ELECTROLYTE MINIMUM LEVEL OF ELECTROLYTE PLATE PROTECTOR TOP OF SEPARATORS

FIGURE 14. ELECTROLYTE LEVEL

THE HYDROMETER NOTE: Some batteries have sealed cells. The specific gravity of the electrolyte cannot be checked on these batteries.

Use a hydrometer to measure the specific gravity of the battery. Make sure there is enough electrolyte in the battery cells. See “How To Add Water”. A high level or low level of the electrolyte can change the specific gravity measurement. When the electrolyte level is low, the percent of sulfuric acid in the electrolyte increases. When

1.280

HIGH FLOAT MEANS HIGH SPECIFIC GRAVITY

LOW FLOAT MEANS LOW SPECIFIC GRAVITY

The temperature of the electrolyte will change the reading of the specific gravity. When the temperature increases approximately 6°C (10°F), the specific gravity will decrease by 0.003 points. See FIGURE 16. for making specific gravity corrections. If the hydrometer you are using does not have a temperature correction, you will have to use a thermometer. Special battery thermometers are available that will indicate the correction factor directly and add or subtract the correct number of points. See FIGURE 17.

Never charge a battery at a rate that will raise the electrolyte temperature above 49°C (120°F). Never let a battery stay discharged for long periods. A temperature above this amount will damage the battery. The cells in the center of the battery are normally at the highest temperature. If the battery temperature is too hot, make sure the ventilation of the battery is increased and make sure that the charge or discharge rate is not too high. A recommendation for a battery in service is 8 hours of use (discharge), followed by 8 hours of cooling, followed by 8 hours of charging.

1.150

CORRECT METHOD OF READING HYDROMETER. EYE LEVEL EVEN WITH THE SURFACE OF THE ELECTROLYTE

FIGURE 15. READING THE HYDROMETER 8

6187

final charging must be at a low rate. A charging rate that is too high will cause heating in the battery and a high loss of water from the electrolyte. The charging of the battery must be done correctly or the service life of the battery will be decreased.

CHARGING THE BATTERY CAUTION Use only battery chargers approved by the battery manufacturer or dealer.

11034

SPECIFIC GRAVITY READING

ELECTRO– CORRECTION CORRECT LYTE POINTS VALUE TEMP.

1.210

31°C (87°F)

+0.003

1.213

1.210 1.210 1.210

27°C (80°F) 25°C (77°F)

+0.001 0.000 –0.004

1.211 1.210 1.206

18°C (64°F)

+0.001 or –0.001 for each 2 degrees C from the 25 degree base value.

FIGURE 16. CHECK SPECIFIC GRAVITY

NOTE: There can be one of two types of batteries. One type has removable cell caps. The other type has sealed cells. The sealed batteries require a different charger.

The electrolyte level or specific gravity cannot be checked and water cannot be added to the electrolyte of these sealed batteries.

WARNING The acid in the electrolyte can cause injury. If electrolyte is spilled, use water to flush the area. Make the acid neutral with a solution of sodium bicarbonate.

Batteries generate explosive fumes when they are being charged. Keep fire, sparks and burning material away from the battery charger area. Prevent sparks from the battery connectors.

Charge batteries only in the special area for charging batteries. When charging the batteries, keep the vent caps clean. The battery charger area must have ventilation so that explosive fumes are removed.

Open the hood over the battery or remove the cover if the battery has a cover.

Disconnect the battery when doing cleaning and maintenance.

6186

FIGURE 17. BATTERY THERMOMETER To charge the battery, a direct current must pass through the cells in the opposite direction to the discharging current. The ampere–hours must be equal to the discharging ampere–hours plus the energy lost as heat. This additional amount of charge will vary according to the battery and the temperature, but the average additional charge is 12%. When the battery is nearly charged, the

If the lift truck has been operated with a low battery, check the contactors for welded contacts before a charged battery is connected. The circuit will not reset and lift truck operation cannot be controlled if the contacts are welded. To check the contacts, see the section EV–100 SCR MOTOR CONTROLLER, 2200 SRM 557 of the SERVICE MANUAL.

CAUTION Never connect the battery charger plug to the plug of the lift truck. You can damage the traction control circuit. Make sure the charger voltage is the correct voltage for the battery.

9

Correct use of the hydrometer (see FIGURE 15.) and proper operation of the battery charger is important.

Also see FIGURE 16. Follow the instructions of the charger manufacturer. Never let the battery discharge below the minimum value given by the battery manufacturer. A fully charged battery will have a specific gravity of 1.265 to 1.310 at 25°C (77°F). See FIGURE 16. Never charge a battery at a rate that will raise the electrolyte temperature above 49°C (120°F).

Never let a battery to stay discharged for long periods.

limits shown. Discharging a battery beyond the design limits will decrease the service life of the battery.

Types Of Battery Charges 1. NORMAL CHARGE: This charge is usually given to a battery that is discharged from normal operation. This is often an eight hours charge. Many customers charge the battery at regular intervals that depend on use. This procedure will keep the battery correctly charged if the battery is not discharged below the limit. Always use a hydrometer to check the battery if the battery is charged at regular intervals. Frequent charging of a battery that has a 2/3 or more charge can decrease the life of the battery.

2. EQUALIZING CHARGE: This charge is at a low rate and balances the charge in all of the cells. The equalizing charge is usually given approximately once a month. It is a charge at a slow rate for three to six hours in addition to the regular charging cycle. Do not give an equalizing charge more than once a week. The most accurate specific gravity measurements for a charged battery will be after an equalizing charge. If the specific gravity difference is more than 0.020 between cells of the battery after an equalizing charge, there can be a damaged cell. Consult your battery dealer.

6185

FIGURE 18. SPECIFIC GRAVITY VERSUS PERCENT DISCHARGE

NOTE: Many customers have battery chargers that can follow a program to automatically charge a battery according to recommendations of the battery manufacturer. Use the recommendations of the battery manufacturer for charging the battery. See the section DC MOTOR MAINTENANCE, 620 SRM 294 for additional information.

6184

The discharge limits and the limits for the specific gravity before the battery must be charged again are shown in FIGURE 18. NEVER discharge a battery below the 10

FIGURE 19. SPECIFIC GRAVITY COMPARED TO CHARGING TIME

3. TWO–RATE CHARGE. This method also uses a high charging rate at the beginning followed by a lower rate. Two resistors control the charging rate. One resistor controls the charging rate at the beginning of the cycle and a second resistor reduces the charging rate when the voltage in the cells reach 2.37 volts. A relay automatically controls the second resistor. The two–rate charging cycle is shown in FIGURE 22.

6173

FIGURE 20. SPECIFIC GRAVITY COMPARED TO CHARGING TIME NOTE: Sometimes the capacity of a battery is not enough to complete a work period. Check for the following conditions: •

The battery is too small for the job.

•

The battery is not fully charged.

•

The battery charger is not operating correctly.

•

The battery is near the end of its service life.

6174

FIGURE 21. MODIFIED CONSTANT VOLTAGE CHARGER

Methods Of Charging There are three methods of charging a battery.

1. GRADUAL CHARGE. This method uses a solid state automatic battery charger. The charging rate begins at 20 to 25 amps/100 amp–hours and decreases to less than 5 amps/100 amp–hours when the battery is 80% charged. The charging current decreases when the voltage across the cell increases during the charging cycle is shown in FIGURE 20. The increase in the voltage from the charger is approximately the same as the increase in the specific gravity in the cells.

2. MODIFIED CONSTANT VOLTAGE. This method uses a generator to generate a constant voltage that is controlled by a resistor. When the charging current decreases, the voltage across the resistor increases. The increasing voltage across the resistor causes an increasing voltage at the battery terminals. The charging is similar to the gradual charge The resistor must be correctly set or the charging rate will be wrong. The typical graphs for a modified constant voltage charger is shown in FIGURE 21.

6175

FIGURE 22. TWO–RATE CHARGING CYCLE NOTE: Many users have battery chargers that can follow a program to automatically charge a battery according to recommendations of the battery manufacturer.

Use the recommendations of the battery manufacturer for charging the battery.

Troubleshooting The Charger Battery chargers normally operate automatically without constant attention. It is necessary to make a periodic 11

check that the charger is operating correctly. Check for the following conditions:

4. Constant meter indications on the charger will indicate the end of the charging cycle.

1. Battery temperature is too high. The temperature in a battery will not normally rise more than 14°C (25°F) during an eight hour charging period. Higher temperatures indicate that the charging rate needs adjustment.

WHERE TO CHARGE THE BATTERIES

2. Continuous operation of the charger. Check the automatic controls on the charger. Check the charging rate.

A low charging rate can be the problem.

3. Continuous operation of a charger at a high rate. Normally, the charging rate begins at a high rate and decreases as the battery becomes charged. If the rate does not decrease, the controls need repair or adjustment.

To increase the service life and reduce maintenance, a special area is needed for charging the batteries. The following information is necessary for the design of this area: •

Location of power supply.

•

Ventilation. Hydrogen gas comes from the batteries during charging.

•

Drains for cleaning the batteries.

•

Type and size of the batteries.

•

Type of lift trucks.

•

Distances that the lift trucks must travel for service.

•

Safety regulations and instructions.

WARNING Always connect the positive cable to the positive terminal and connect the negative cable to the negative terminal. Any other connection will cause injury and damage.

Always charge the battery at the end of the work period (shift). Never let the specific gravity decrease to a level less than the limits shown in the manual.

Equipment Needed •

A lifting device to remove the battery from the lift truck.

•

Racks to hold the batteries during charging and storage. These racks must be made of wood or must not be metal. Metal racks that are covered with an insulating material can be used.

•

A battery charger that will charge your batteries.

•

Tools for maintenance.

•

An area with a drain for cleaning batteries and battery compartments.

•

Distilled water.

•

Air and water supplies for cleaning.

•

Maintenance records. See FIGURE 11. and FIGURE 12.

•

A work bench.

•

Spare parts and repair equipment.

•

Protective clothing and safety equipment for handling batteries.

•

Water source for washing eyes and preventing acid burns.

•

Install a NO SMOKING sign in the service area.

•

Keep the charger in a clean, dry area with good ventilation.

Always deenergize the charger before you connect or disconnect the charger from the battery.

Never connect the battery charger plug to the plug of the lift truck. You can damage the traction control circuit. Make sure the charger voltage is the correct voltage for the battery.

How To Know When The Battery Is Fully Charged 1. During charging, the voltage increases slowly. When the battery is fully charged, the voltage level is constant.

2. Remove a vent cap and look in the opening. If you see bubbles in the electrolyte, the battery is either fully charged or in the final stage of charging.

3. The specific gravity reading is constant and within the limits of a charged battery. If the temperature increases after the battery is charged, the specific gravity will decrease a small amount.

12

1 3 4

handle must be kept in good repair so that it will function correctly. The battery connector must be disconnected when maintenance is done on the lift truck that does not require electric power. The SBE, SBX, and FEM or DIN 12 volt battery connectors are shown in FIGURE 24.

BATTERY CARE 1. Keep batteries clean. Remove any spilled electrolyte.

4

2

2. Do not over–charge the battery. This action will damage the battery.

3. Do not discharge the battery to less than the recommendation. A deep discharge will shorten the battery life.

4. Charge batteries in an area with good ventilation to remove explosive gases and acid fumes.

1. SB CONNECTOR FOR BATTERY CABLES 2. SB CONNECTOR FOR POWER CABLES TO LIFT TRUCK 3. BRACKET 4. CONNECT AND DISCONNECT HANDLES

FIGURE 23. THE SB BATTERY CONNECTOR

BATTERY CONNECTORS A special heavy–duty connector is used to connect the battery to the electrical system of the lift truck. See FIGURE 23. Also see FIGURE 24. When a connector has a handle and is within the operator’s reach, the connector is also a safety device that can be used to quickly disconnect the battery in an emergency. Most connectors have a handle to connect the two halves of the connector. The connector can be quickly disconnected by pulling the handle upward. This action separates the two halves of the connector. The connector and its attached

5. Keep the electrolyte at the correct level. Check the electrolyte level before and after charging the battery.

Use distilled water. Do not add acid.

6. Prevent batteries from freezing.

7. Keep batteries charged. A discharged battery in storage will shorten the battery life.

8. Use a battery charger that is correct for the battery. A battery charger that is set for an ampere–hour rate that is too high will cause a high internal heat and damage the battery. A low ampere–hour rate setting on a battery charger can require a longer charging time but will not damage the battery.

9. When batteries are moved, make sure a short–circuit does not occur. See the Safety Procedures in BATTERY MAINTENANCE of this section.

13

2

3 INDICATOR INSERT (Item 2) Green – For Battery With Cell Caps Gray – For Battery With Sealed Cells

4

5 5

1

10

6

11

1

12 12866

7

8

8

1364973 R0

9 ANDERSON SBE OR SBX CONNECTOR CONNECTOR BODY COLOR (Anderson SBE Connector Only) (Item 1) Gray – 36 Volt Battery Blue – 48Volt Battery Green – 72 Volt Battery Black – 80 Volt Battery

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

9 9 12866

FEM OR DIN CONNECTOR

HALF OF CONNECTOR SET RED HOUSING FOR +12 VOLT “BATTERY TAP” LOCK SPRING (TIP OF CONTACT MUST LOCK OVER TOP OF LOCK SPRING) BLACK CONNECTOR HOUSING (ASSEMBLED ON RED HOUSING WITH SLOTS FOR LOCK PINS ALIGNED AS SHOWN – NO WIRE OR CONTACT IN HOUSING) SLOT FOR LOCK PIN CONTACT FOR CONNECTOR OF +12 VOLT BATTERY TAP KEY [RED (Item 2) AND BLACK (Item 4) CONNECTORS ALIGN ON KEY] LOCK PINS FOR +12 VOLT CONNECTOR (MUST INSTALL FROM FRONT OF CONNECTOR THROUGH RED & BLACK CONNECTORS) +12 VOLT WIRE TO TRUCK (TRUCK HALF) OR TO BATTERY (BATTERY HALF) INDICATOR INSERT FOR BATTERY VOLTAGE AND BATTERY TYPE [ROTATE FOR CORRECT VOLTAGE IN WINDOW (Item 12). COLOR SHOWS BATTERY TYPE} LOCK FOR ALL CABLE TERMINALS AND INDICATOR WINDOW SHOWING BATTERY VOLTAGE IN–LINE FUSE ASSEMBLY AND CONTACT FOR +12 VOLT CONNECTOR (TRUCK HALF OF BATTERY CONNECTOR ONLY) (SBE/SBX CONTACT SHOWN)

FIGURE 24. DETAIL OF BATTERY CONNECTORS WITH +12 VOLT TAP 14

/,)7 &</,1'(56 ALL, EXCEPT H7.00-12.50H (H150-275H), H13.50-16.00B (H300-350B), H16.00-30.00C (H360-650C), H32.00-42.00B (H700-920B)

PART NO. 910119

4000 SRM 135

SAFETY PRECAUTIONS MAINTENANCE AND REPAIR • When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and that the load being lifted is balanced. Make sure the crane, cables, and chains have the capacity to support the weight of the load.

• Do not lift heavy parts by hand, use a lifting mechanism.

• Wear safety glasses.

• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift trucks.

• Disconnect the battery ground cable on internal combustion lift trucks.

• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance section.

• Keep the unit clean and the working area clean and orderly.

• Use the correct tools for the job.

• Keep the tools clean and in good condition.

• Always use HYSTER APPROVED parts when making repairs. Replacement parts must meet or exceed the specifications of the original equipment manufacturer.

• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to remove parts.

• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the unit needs repairs.

• Be sure to follow the WARNING and CAUTION notes in the instructions.

• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are flammable. Be sure to follow the necessary safety precautions when handling these fuels and when working on these fuel systems.

• Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the area. Make sure the area is well ventilated.

NOTE: The following symbols and words indicate safety information in this manual:

WARNING Indicates a condition that can cause immediate death or injury!

CAUTION Indicates a condition that can cause property damage!

4000 SRM 135

Safety Procedures When Working Near Mast

Safety Procedures When Working Near Mast The following procedures must be used when inspecting or working near the mast. Additional precautions and procedures can be required when repairing or removing the mast. See the correct Service Manual section for the specific mast being repaired.

WARNING Mast parts are heavy and can move. Distances between parts are small. Serious injury or death can result if part of the body is hit by parts of the mast or the carriage.

• Never put any part of the body into or under the mast or carriage unless all parts are completely lowered or a safety chain is installed.

Also make sure that the power is OFF and the key is removed. Put a "DO NOT OPERATE" tag in the operator’s compartment.

• Be careful of the forks. When the mast is raised, the forks can be at a height to cause an injury.

• Do NOT climb on the mast or lift truck at any time. Use a ladder or personnel lift to work on the mast.

• Do NOT use blocks to support the mast weldments nor to restrain their movement.

• Mast repairs require disassembly and removal of parts and can require removal of the mast or carriage. Follow the repair procedures in the correct Service Manual for the mast.

OR 2. If parts of the mast must be in raised position, install a safety chain to restrain the moving parts of the mast. Connect moving parts to a part that does not move. Follow these procedures: a. Put the mast in a vertical position. b. Raise the mast to align the bottom crossmember of the inner weldment with a crossmember on the outer weldment. See Figure 1. c. Use a 12 mm (0.5 in.) minimum safety chain with a hook to fasten the crossmembers together so that the movable member cannot lower. Put the hook on the back side of the mast. Make sure the hook is completely engaged with a link in the chain. Make sure the safety chain does not touch lift chains or chain sheaves, tubes, hoses, fittings or other parts on the mast. d. Lower the mast until there is tension in the safety chain. If running, stop the engine. Apply the parking brake. Install a "DO NOT REMOVE" tag on the safety chain(s). e. Install another safety chain 12 mm (0.5 in.) minimum between the top or bottom crossmember of the carriage and a crossmember on the outer weldment.

WHEN WORKING NEAR THE MAST ALWAYS: 1. Lower the mast and carriage completely. Push the lift/lower control lever forward and make sure there is no movement in the mast. Make sure that all parts of the mast that move are fully lowered.

3. Apply the parking brake. After lowering or restraining the mast, shut off the power and remove the key. Put a "DO NOT OPERATE" tag in the operator’s compartment.

1

Safety Procedures When Working Near Mast

1. INNER WELDMENT

4000 SRM 135

2. OUTER WELDMENT

3. HOOK

4. CARRIAGE

Figure 1. Mast The following procedures must be used when inspecting or working near the mast. Additional precautions and procedures can be required when repairing or removing the mast. See the correct Service Manual section for the specific mast being repaired.

WARNING Mast parts are heavy and can move. Distances between parts are small. Serious injury or death can result if part of the body is hit by parts of the mast or the carriage.

• Never put any part of the body into or under the mast or carriage unless all parts are completely lowered or a safety chain is installed.

Also make sure that the power is OFF and the key is removed. Put a "DO NOT OPERATE" tag in the operator’s compartment.

2

• Be careful of the forks. When the mast is raised, the forks can be at a height to cause an injury.

• Do NOT climb on the mast or lift truck at any time. Use a ladder or personnel lift to work on the mast.

• Do NOT use blocks to support the mast weldments nor to restrain their movement.

• Mast repairs require disassembly and removal of parts and can require removal of the mast or carriage. Follow the repair procedures in the correct Service Manual section for the mast.

WHEN WORKING NEAR THE MAST ALWAYS: 1. Lower the mast and carriage completely. Push the lift/lower control lever forward and make sure there is no movement in the mast. Make

4000 SRM 135

Safety Procedures When Working Near Mast

sure that all parts of the mast that move are fully lowered.

OR 2. If parts of the mast must be in raised position, install a safety chain to restrain the moving parts of the mast. Connect moving parts to a part that does not move. Follow these procedures: a. Put the mast in a vertical position. b. Raise the mast to align the bottom of the inner weldment to below the anchor for the tilt cylinders. See Figure 2.

1. INNER WELDMENT

c. Use a 12 mm (0.5 in.) minimum safety chain with a hook to fasten the weldments together so that the inner weldment cannot lower. Install the chain on both sides of the mast.

Make sure the hooks are completely engaged with a link in the chain. d. Lower the mast until there is tension in the safety chain. If the engine is running, stop the engine. Apply the parking brake. Install a "DO NOT REMOVE" tag on the safety chain. Put a "DO NOT OPERATE" tag in the operator’s compartment.

2. TILT CYLINDERS

3. HOOK

Figure 2. Mast

3

Safety Procedures When Working Near Mast The following procedures must be used when inspecting or working near the mast. Additional precautions and procedures can be required when repairing or removing the mast. See the correct Service Manual section for the specific mast being repaired.

WARNING Mast parts are heavy and can move. Distances between parts are small. Serious injury or death can result if part of the body is hit by parts of the mast or the carriage.

• Never put any part of the body into or under the mast or carriage unless all parts are completely lowered or a safety chain is installed.

Also make sure that the power is OFF and the key is removed. Put a "DO NOT OPERATE" tag in the operator’s compartment.

• Be careful of the forks. When the mast is raised, the forks can be at a height to cause an injury.

• Do NOT climb on the mast or lift truck at any time. Use a ladder or personnel lift to work on the mast.

• Do NOT use blocks to support the mast weldments nor to restrain their movement.

• Mast repairs require disassembly and removal of parts and can require removal of the mast or carriage. Follow the repair procedures in the correct Service Manual section for the mast.

WHEN WORKING NEAR THE MAST ALWAYS: 1. Lower the mast and carriage completely. Push the lift/lower control lever forward and make sure there is no movement in the mast. Make sure that all parts of the mast that move are fully lowered.

OR 2. If parts of the mast must be in raised position, install a safety chain to restrain the moving parts

4

4000 SRM 135 of the mast. Connect moving parts to a part that does not move. Follow these procedures: a. Put the mast in a vertical position. b. Raise the mast to align the bottom crossmember of the weldment that moves in the outer weldment with a crossmember on the outer weldment. On the two-stage and freelift mast, the moving part is the inner weldment. On the three-stage mast, it is the intermediate weldment. On the four-stage mast, it is the first intermediate weldment.

See Figure 3. c. Use a 10 mm (0.375 in.) minimum safety chain with a hook to fasten the crossmembers together so that the movable member cannot lower. Put the hook on the back side of the mast. Make sure the hook is completely engaged with a link in the chain. Make sure the safety chain does not touch lift chains or chain sheaves, tubes, hoses, fittings or other parts on the mast. d. Lower the mast until there is tension in the safety chain and the free-lift cylinder (freelift and three-stage masts only) is completely retracted. If the engine is running, stop the engine. Apply the parking brake. Install a "DO NOT REMOVE" tag on the safety chain(s). e. Install another safety chain 10 mm (0.375 in.) minimum between the top or bottom crossmember of the carriage and a crossmember on the outer weldment.

3. Apply the parking brake. After lowering or restraining the mast, shut off the power and remove the key. Put a "DO NOT OPERATE" tag in the operator’s compartment.

4000 SRM 135

Safety Procedures When Working Near Mast

Figure 3. Two-Stage, Free-Lift, Three-Stage, and Four-Stage Masts

5

Description

4000 SRM 135 Legend for Figure 3

A. TWO-STAGE MAST B. FREE-LIFT MAST

C. THREE-STAGE MAST D. FOUR-STAGE MAST

1.

2.

3.

4.

5.

6.

7.

8.

OUTER WELDMENT INNER WELDMENT INTERMEDIATE WELDMENT FIRST INTERMEDIATE WELDMENT

HOOK FREE-LIFT CYLINDER CROSSMEMBER CROSSMEMBER

General This section has the description for lift cylinders used in masts and the instructions for their repair. There are many different sizes of lift cylinders used in Hyster Company lift trucks. The operation and repair procedures for the different lift cylinders are similar. The illustrations in this section are for typical

lift cylinders. All of the variations in lift cylinders used in lift trucks are not shown. A section for Lift Cylinders For VISTA® Masts is included later in this section.

Description All lift cylinders are single-acting cylinders. See Figure 4. The hydraulic force is applied only in one direction. When hydraulic oil enters one end of the lift cylinder, the hydraulic force extends the piston rod.

When the force is removed, the weight of the carriage and inner mast retracts the piston rod.

A common maintenance problem is the repair of oil leaks from the seals and wiper around the piston rod.

If the bore of the shell of the lift cylinder is damaged and cannot be repaired, the lift cylinder must be replaced.

Lowering Control Valve A lowering control valve is installed in the inlet port.

See Figure 5. It permits easy entry of hydraulic oil into the cylinder, but gives a restriction when the rod is retracted. This restriction gives limits to the speed that a load on the forks can be lowered.

There are two types of lowering control valves. Both types have the same function and similar operation.

The most common type of valve has a design that has good operation using large flows and lower pressures. Some lift trucks have a lift system design using higher pressures and a lower flow. These systems need a different type of lowering control valve.

6

The most common type of lowering control valve uses these parts: (1) a special fitting for the valve body, (2) a spring, and (3) a special washer. There is a variation in the shapes of the special washer. Different lift cylinders use different shapes of special washers.

The volume of the hydraulic oil flowing through the inlet port controls the shape of the special washer.

(A typical shape of a special washer is shown in Figure 5.) When the piston rod is lowered, the oil flow pushes against the special washer and spring. When the oil flow reaches the limit, the special washer is moved against the special fitting. The oil then flows only through the hole in the center of the special washer. This restriction permits the piston rod to lower only at a maximum controlled speed.

The other type of lowering control valve uses these basic parts: (1) valve body, (2) spring, (3) washer, (4) cylinder, (5) orifice sleeve, (6) plunger, and (7) main sleeve. The orifice sleeve position is controlled completely by oil flow. The plunger position is controlled by oil pressure and spring tension. During lifting, oil entering the lift cylinder goes through the center of the main sleeve to the large holes. The oil flow through the plunger and bore moves the orifice sleeve to the end of the plunger. The flange of the orifice sleeve is then aligned with the large part of the bore in the body. This alignment lets the oil flow past the orifice sleeve to the cylinder.

4000 SRM 135

Description

A. INSTALLED

B. NOT INSTALLED

1.

2.

3.

4.

5.

6.

7.

8.

LOWERING CONTROL VALVE PISTON BEARING CHECK VALVE

SHELL NYLON RING RETAINER WIPER SEAL

9.

10.

11.

12.

BACK-UP RING O-RING ROD SINGLE-LIP SEAL

Figure 4. Two-Speed Lift Cylinder

7

Description

4000 SRM 135

A. LOW PRESSURE DESIGN B. LOWERING

C. RESTRICTED FLOW D. HIGH PRESSURE DESIGN

E. LIFTING F. FREE FLOW

1. SPECIAL FITTING OR VALVE BODY 2. SPRING

3. SPECIAL WASHER 4. CYLINDER 5. ORIFICE SLEEVE

6. PLUNGER 7. MAIN SLEEVE

Figure 5. Lowering Control Valves During lowering, oil from the lift cylinder moves the orifice sleeve. The orifice sleeve moves away from the larger inner diameter area of the bore in the valve body. This movement makes a restriction to the oil flow. As the pressure increases, the plunger begins to move against the spring. The movement begins to close the openings of the large holes in the main

8

sleeve. Additional pressure will push the plunger against the main sleeve to close the large holes completely. All the oil must then go through the small holes to the center of the main sleeve. This restriction permits the piston rod to lower only at a maximum controlled speed.

4000 SRM 135

Cylinders (General) Standard masts use a single-stage lift cylinder.

Most three-stage and four-stage masts use two single-stage lift cylinders. A single-stage lift cylinder has one piston rod. See Figure 6.

Most full free-lift masts and some three-stage masts use a two-stage lift cylinder. A two-stage lift cylinder has two telescopic piston rods. See Figure 7. The two-stage lift cylinder operates similar to a one-stage lift cylinder. Hydraulic pressure pushes the primary (larger) piston rod from the cylinder first because it has a larger diameter. The secondary piston rod moves with the primary piston rod. When the primary piston rod reaches the limit of its stroke, the secondary piston rod extends from the primary piston rod.

Spacers are used in some cylinders to give a limit to the stroke of the piston rod. Worn spacers must be replaced with the same size spacer.

Most of the lift cylinders use a single-lip seal assembly to prevent hydraulic oil leaks past the piston and past the retainer. See Figure 4. There are many lift cylinders in use that have an older design chevron-style packing. The chevron-style packing can be replaced with a seal kit that has the newer single lip seal and an adaptor. There are no replacements of single lip seals for chevron-style packing for lift trucks over 7,000 kg (15,000 lb) capacity.

Lift cylinders and other hydraulic parts can have internal leaks. Internal leakage will increase as the temperature of the hydraulic oil increases. The internal leak rate of the hydraulic system is normally checked after every 1000 hours of operation. See Lift System Leak Check for test procedures and leakage rates within the specifications.

During operation, some leakage of hydraulic oil can move past the piston seal to the rod side of the piston. A small leakage is permitted if the internal leak rate of the hydraulic system is not greater than the specification. An internal check valve is installed in

Description the piston of many of the lift cylinders. When the rod extends, the pressure increases more quickly on any oil in the rod end of the cylinder. The hydraulic oil transfers through the check valve to the piston end of the cylinder. This action prevents hydraulic damage to the wiper seal. See Figure 8. Lift cylinders that do not have an internal check valve have a drain line on the outside of the cylinder shell.

Cylinders (H520-620B, H700-800A) The rod side of the lift cylinder is used for the storage of hydraulic oil on the H520-620B and H700-800A lift trucks. This storage decreases the required size of the hydraulic tank. When the piston raises in the cylinder, the oil on the rod side of the piston transfers to the hydraulic tank. When the piston lowers in the cylinder, some of the oil transfers to the rod side of the cylinder. Approximately one half of the oil in the bottom of the cylinder goes through the main control valve to the rod side of the cylinder. See the Main Control Valve of Service Manual for more information. See Figure 9.

Retainer, Install 1. Install the retainer over the piston and into the cylinder. Make sure the single-lip seal assembly, the O-ring, and the back-up ring are not damaged. See Figure 9.

2. Turn the retainer ring into the threads in the cylinder. Turn the retainer ring until it is even with the top of the cylinder.

3. Install the capscrews loosely.

4. The stroke of the cylinder rod can be adjusted by turning the retainer ring one-half turn in either direction.

5. Install and tighten the setscrew.

6. Tighten the capscrews to 36 to 46 N•m (27 to 34 lbf ft).

9

Description

4000 SRM 135

A. MAIN LIFT CYLINDER

B. FREE-LIFT CYLINDER

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

WIPER RING SINGLE-LIP SEAL BEARING O-RING RETAINER CHAIN ANCHOR MOUNT

HYDRAULIC LINE MOUNT INTERNAL CHECK VALVE ROD ASSEMBLY SPACER TO SENSING PORT FOR PHASING VALVE PRESSURE

12. LOWERING CONTROL VALVE (ALL CYLINDERS) 13. PISTON RING 14. CUSHION RING

Figure 6. Single-Stage Lift Cylinders

10

4000 SRM 135

Description

A. INSTALLED

B. NOT INSTALLED

1.

2.

3.

4.

5. SINGLE-LIP SEAL 6. O-RING 7. NYLON BACK-UP RING

POPPET SPRING SEAL INLET AND OUTLET PORT

Figure 8. Internal Check Valve and Single-Lip Seal 1.

2.

3.

4.

WIPER RING RETAINER SEAL SCREW (DO NOT CHANGE LENGTH) 5. PRIMARY ROD ASSEMBLY 6. SPACERS 7. BEARING

8. PISTON HALF (1 OF 2) 9. INTERNAL CHECK VALVE 10. SINGLE-LIP SEAL 11. SECONDARY ROD ASSEMBLY 12. O-RING 13. PLUG

Figure 7. Two-Stage Lift Cylinder

Cylinders (H360-460B) The lift cylinders used in the H360-460B lift trucks are displacement cylinders. The design and repairs for these cylinders are similar to the other lift cylinder in this section. A displacement cylinder does not have a piston or piston seal. The rod diameter is almost the same as the inside diameter of the cylinder. There are wear rings on the rod that are the bearings between the rod and the walls of the cylinder. The wiper seal at the top of the cylinder is also the high-pressure seal for these cylinders. The wiper seal has chevron-style packing. See Figure 10.

11

Description

4000 SRM 135

A. LOWERING CONTROL VALVE 1.

2.

3.

4.

SETSCREW (1) CAPSCREW (2) RETAINER RING SINGLE-LIP SEAL ASSEMBLY

5.

6.

7.

8.

9.

RETAINER BACK-UP RING O-RING CYLINDER SHELL ROD

10.

11.

12.

13.

14.

SPACER PISTON PISTON RING NUT NYLON SETSCREW SPRING

Figure 9. Lift Cylinder for H700-800A

12

15.

16.

17.

18.

19.

FLANGE SPACER PLATE SPACER VALVE BODY SPECIAL WASHER

4000 SRM 135

Description Legend for Figure 10 NOTE: OIL LEAKAGE IS NOT CONTROLLED BY THE TORQUE ON THE PACKING GLAND. TIGHTEN THE PACKING RETAINER TO STOP OIL LEAKS. REPLACE CHEVRON-STYLE PACKING WHEN PACKING RETAINER CANNOT COMPRESS PACKING FURTHER TO CONTROL OIL LEAKS. DO NOT TIGHTEN MORE THAN NECESSARY TO STOP OIL LEAKS. 1. WIPER 2. NYLON RING 3. CHEVRON-STYLE PACKING 4. BACK-UP RING 5. O-RING 6. ROD HEAD

7. PACKING RETAINER 8. PACKING GLAND 9. CYLINDER SHELL 10. INLET AND OUTLET PORT 11. WEAR RING

Figure 10. Displacement Cylinders

13

Description

4000 SRM 135

Cylinders (Two-Speed) Two-speed lift cylinders are single-stage lift cylinders with a special valve and path for the hydraulic oil.

The lift cylinder is filled with oil on both sides of the piston. For loads less than 45% of the rated capacity, the cylinder rod can be extended at high speed. When the cylinder rod extends, the oil on the rod side of the

piston transfers to the bottom of the piston. When the oil transfers, the increase almost doubles the flow of oil to the base of the cylinder. The pump pressure is applied to both sides of the piston. The area on the bottom of the piston is greater than the rod side of the piston. The difference in force pushes the piston up the cylinder. See Figure 11.

A. HIGH-SPEED OPERATION FOR NO LOAD OR LIGHT LOADS B. NORMAL OPERATION FOR RATED CAPACITY LOAD OR HEAVY LOADS 1. FORCE 2. FROM HYDRAULIC PUMP

3. GREATER LIFTING FORCE 4. TO HYDRAULIC TANK Figure 11. Two-Speed Lift Cylinders

For loads greater than 45% of capacity, the cylinder rod extends at normal speed. A special valve senses the increased oil pressure caused by the load. The oil is returned from the rod side of the lift cylinder to the hydraulic tank. All of the pump pressure is applied to the bottom side of the piston. The cylinder rod extends at a slower speed, but can lift a greater load. The two-speed lifting system is used only with standard masts. A two-speed lift system is used on the following lift trucks:

14

S60-80B

H150-250E

S125-150A

H150-275H

H60-80C

H250-300A

H300-350B

P125-180A

H110-150F

P150-200B

NOTE: The maximum loads that the above models will lift at high speed are shown on Table 1.

4000 SRM 135

Lift Cylinder Repair Table 1. Lift Trucks with Two-Speed Lift Cylinders

Model

Load

S60-100B

1589 to 2043 kg (3500-4500 lb)

H60-80C

1589 to 2043 kg (3500 to 4500 lb)

H110-150F

1589 to 2043 kg (3500 to 4500 lb)

S125-150A

2270 to 2724 kg (5000 to 6000 lb)

H150-200ES, Standard Masts

2270 to 3087 kg (5000 to 6800 lb)

P125-180A, Standard Masts

2270 to 3087 kg (5000 to 6800 lb)

H150-250E, Heavy Duty Masts

3133 to 4041 kg (6900 to 8900 lb)

P125-180A, Heavy Duty Masts

3133 to 4041 kg (6900 to 8900 lb)

H250-300A

4540 to 4994 kg (10,000 to 11,000 lb)

This table shows the approximate maximum load that the mast will lift at high speed. Loads greater than those shown will cause the mast to lift at normal speed. These loads will have a variation because of the different attachments that can be installed on the lift truck.

Lift Cylinder Repair LIFT CYLINDER REMOVAL WITHOUT REMOVING MAST Remove the carriage before the lift cylinder. See the procedure described in the Masts section. If the mast must be removed for repairs, then remove the lift cylinder when the mast is disassembled. Remove the lift cylinder from the mast as described in the following paragraphs.

Standard Masts with Main Lift Cylinder Fastened to Crossmember of Inner Mast 1. Fully lower the mast. Loosen, but do not disconnect the capscrew that fastens the cylinder rod to the crossmember of the inner mast.

2. Clean the area next to the fittings that connect the hydraulic lines to the lift cylinder. Put a drain pan under the area where the hydraulic lines will be disconnected. Disconnect the hydraulic lines and put a cap on each open fitting.

WARNING Make sure the lifting mechanism has enough capacity to lift the loads. See the Weight Guide for lift cylinders in Table 1.

3. Connect a lifting mechanism to the inner mast.

Lift the inner mast approximately 300 mm (12 in.). Fasten the inner and outer masts together at the crossmembers with a heavy chain.

Make sure that the inner mast cannot move.

Remove the lifting mechanism.

4. Connect a heavy-duty sling to the upper part of the cylinder. Raise the lifting mechanism until the sling is tight. Make sure the sling will not slide.

5. Remove the capscrew and washer connecting the piston rod to the inner mast. Remove the spacer.

CAUTION Oil can come out of the cylinder fittings with pressure when retracting the rod.

6. Loosen the cap on the lower fitting of the cylinder.

Manually retract the piston rod.

7. Remove the capscrew and the plate from the lower side of the cylinder.

8. Raise the cylinder and move it away from the mast. Move the lift cylinder to a position where it can be disassembled.

15

Lift Cylinder Repair

4000 SRM 135

Standard and Full Free-Lift Masts with Lift Cylinder Fastened to Crosshead 1. Remove the lift chains and chain anchors from the mast and the lift cylinder. Connect a sling to the upper area of the lift cylinder. Raise the lifting mechanism until the sling is tight. See Figure 12 and Figure 13.

1.

2.

3.

4.

SHEAVE SNAP RING CROSSHEAD CYLINDER GUIDE ASSEMBLY

5.

6.

7.

8.

9.

CHAIN ANCHOR WASHER AND NUT SHIM GUIDE SHOE BEARING

Figure 13. Free-Lift Cylinder and Crosshead 2. Remove the capscrews that connect the piston rod to the crosshead.

3. Disconnect and remove the crosshead assembly from the mast. Make a note of the shim arrangement on the crosshead guide.

1. CHAIN GUARD 2. CROSSHEAD ASSEMBLY 3. SNAP RING 4. SHEAVE 5. BEARING

6.

7.

8.

9.

10.

11.

CHAIN ANCHOR SPECIAL WASHER LOCK NUT SPACER WEAR PLATE PAD

Figure 12. Standard Mast Cylinder and Crosshead

4. Clean the area next to the fittings that connect the hydraulic lines to the lift cylinder. Put a drain pan under the area where the hydraulic lines will be disconnected. Disconnect the hydraulic lines and put a cap on each open fitting.

5. Remove the snap ring that connects the bottom of the lift cylinder to the outer mast.

6. Raise the lift cylinder and move it away from the mast. Move the lift cylinder to a position where it can be disassembled.

16

4000 SRM 135

Masts that have Two Cylinders, Main Lift Cylinder and Free-Lift Cylinder 1. Remove the free-lift cylinder as described in the section above for removing a lift cylinder fastened to a crosshead.

2. Remove the main lift cylinder as described in the section above for removing a lift cylinder fastened to an inner mast.

DISASSEMBLE WARNING Use slings and a crane to handle and disassemble the lift cylinders of most lift trucks. Make sure that the crane and slings can lift the load.

See Table 1.

CAUTION Carefully disassemble and assemble the lift cylinders so that the rods and sliding surfaces are not damaged.

NOTE: Disassembly of single-stage and two-stage lift cylinders is the same except the two-stage lift cylinder has a second piston rod assembly. The disassembly of the secondary piston rod assembly is similar to the disassembly of the primary piston rod assembly.

1. Loosen the retainer with a spanner. Disconnect the retainer from the shell. See Figure 14 and Figure 15.

2. Remove the cap from the inlet and slide the piston rod assembly from the shell. Use drain pans for the hydraulic oil.

3. Remove the retainer from the piston rod. Remove and discard the O-rings, seals, and bearings.

4. Remove the internal check valve.

5. Remove the lowering control valve.

6. Clean all the parts. Check the sliding surfaces for damage. Repair or replace any damaged parts.

Lift Cylinder Repair

ASSEMBLE NOTE: Lubricate all internal parts of the lift cylinder with hydraulic oil during assembly.

Use new O-rings, seals and bearings. Apply lubricant during assembly. Packing lubricant (Part Number 186061) is available.

Make sure the single-lip seal assemblies are installed with the O-ring towards the base of the lift cylinder.

See Figure 8.

The spacers control the maximum stroke of the piston rod assembly. If a new spacer is necessary, make sure the same size spacer is installed.

1. Install the internal check valve. Make sure the arrow on the internal check valve is toward the base of the piston.

CAUTION A difficult and important step in assembling cylinders is the correct installation of the seals without damage. Most cylinder maintenance is caused by seal leakage.

2. Install the seal and bearing (and spacer if equipped) on the rod piston. Use shim material and a band clamp as a guide to move the single-lip seal past the threads of the shell.

3. Carefully push piston and piston rod into the shell. Release the band clamp on the seal when the seal travels past the threads of the shell.

4. Install the seals, O-rings, and bearings (when used) in the retainer. If the wiper seal has a spring backup ring, the spring must be towards the base of the lift cylinder.

5. Carefully install the retainer on the piston rod.

6. Engage the threads and tighten the retainer in the shell to the correct torque. Use a correct spanner. Do not hit the retainer with a hammer and driver.

17

Lift Cylinder Repair

1.

2.

3.

4.

5.

PLUG O-RING RETAINER WIPER RING SINGLE-LIP SEAL

4000 SRM 135

6.

7.

8.

9.

10.

BEARING O-RING CYLINDER SHELL CYLINDER ROD SPACER

11. INTERNAL CHECK VALVE 12. O-RING 13. WASHER 14. SNAP RING

15. BACKUP RING 16. SINGLE-LIP SEAL 17. BEARING

Figure 14. Single-Stage Lift Cylinder

1.

2.

3.

4.

5.

6.

7.

8.

PLUG RETAINER BEARING O-RING SINGLE-LIP SEAL WIPER RING RETAINER SECONDARY CYLINDER ROD

9.

10.

11.

12.

13.

14.

15.

16.

SPACER BEARING SINGLE-LIP SEAL BACKUP RING PRIMARY CYLINDER ROD SPACER O-RING PISTON RING HALF (2)

Figure 15. Two-Stage Lift Cylinder

18

17.

18.

19.

20.

21.

22.

SNAP RING WASHER INTERNAL CHECK VALVE CYLINDER SCREW SEAL

4000 SRM 135

CAUTION When the screw is installed on two-stage cylinders, never use a screw longer than 9.5 mm (0.375 in.). A longer screw will touch and damage the primary piston rod. Always install a seal under the head of the screw. If you do not install the screw and seal, the cylinder will have leaks.

7. Install the lowering control valve. Make sure the special washer and the spring are installed correctly. A wrong installation can cause the load to lower too fast.

LIFT CYLINDER INSTALLATION IN MAST Standard Masts with Main Lift Cylinder Fastened to Crossmember of Inner Mast

Lift Cylinder Repair 8. Install the carriage.

Standard and Full Free-Lift Masts with Lift Cylinder Fastened to Crosshead 1. Put the lift cylinder into position in the mast.

Align the guide pin with the hole in the bottom crossmember.

2. Install the crosshead assembly in the mast.

Align the holes in the piston rod and the crosshead.

3. Fasten the crosshead to the piston rod with capscrews.

4. Fasten the base of the lift cylinder to its mount with a snap ring.

5. Connect the hydraulic lines.

1. Put the lift cylinder into position in the mast.

Make sure the base of the lift cylinder is aligned correctly on its mount.

6. Install the chain anchors.

2. Connect a chain to the upper section of the lift cylinder and the overhead guard. Make sure the chain will hold the lift cylinder in position until it can be fastened to the mast.

8. Install the carriage. See masts section for checks and adjustments.

3. Connect a lifting mechanism to the inner mast.

The replacement seal kits for chevron-style packing have a single-lip seal and an aluminum spacer. The seal kits also have one or two backup rings. If one backup ring is in the seal kit, install it as shown in B of Figure 16. Two backup rings are installed as shown in C of Figure 16. Make sure the single-lip seal is always installed correctly against the direction of pressure.

CAUTION Do not connect a wrench to the sliding surface of the piston rod. Any damage to the sliding surface will cause leaks.

4. Disconnect the inner mast from the outer mast.

Lower the inner mast until it touches the piston rod. Align the holes of the inner mast and the piston rod.

5. Install capscrews, washer, and spacer to fasten the lift cylinder to the crossmember of the inner mast.

6. Fasten the base of the lift cylinder to the crossmember of the outer mast with a capscrew and plate.

7. Connect the hydraulic lines.

7. Install the lifting chains.

CHEVRON-STYLE PACKING

The installation of chevron-style packing on a piston is shown in Chevron-Style Packing Installation on Piston. The installation of chevron-style packing in a packing gland nut used at the top of the cylinder is shown in Chevron-Style Packing Installation in Packing Gland. There will be some variation in the design of the different lift cylinders. The principles of installation of the chevron-style packing is similar.

Lubricate the parts with hydraulic oil or packing lubricant (Part No. 186061) before assembly.

19

Lift Cylinder Repair

4000 SRM 135

A. MANY EARLIER PRODUCTION LIFT TRUCKS WITH LESS THAN 7000 kg (15,000 lb) CAPACITY THAT HAVE CHEVRON-STYLE PACKING CAN BE CHANGED TO SINGLE-LIP SEALS. B. THE PARTS ARE INSTALLED IN THE ARRANGEMENT SHOWN. C. IF TWO BACKUP RINGS ARE IN THE SEAL KIT, THE PARTS ARE INSTALLED IN THE ARRANGEMENT SHOWN. 1. CHEVRON-STYLE PACKING 2. ALUMINUM SPACER

3. BACKUP RING 4. SINGLE-LIP SEAL ASSEMBLY

5. DIRECTION OF OIL PRESSURE

Figure 16. Chevron-Style Packing Replacement Seal Kits

Chevron-Style Packing Installation on Piston STEP 1.

Lubricate the new O-ring with hydraulic oil and then install it on the piston end of the cylinder rod.

STEP 2.

Install a new packing assembly on the piston half.

The packing must extend approximately 3 mm (1/8 in.) beyond the end of the piston half.

1. THIS RING MUST EXTEND 3 mm (1/8 in.)

BEYOND END OF PISTON HALF.

20

4000 SRM 135

Lift Cylinder Repair

STEP 3.

Install the piston half and snap ring.

STEP 4.

Install the nylon spacer.

STEP 5.

Install the piston in the lift cylinder. Carefully push the piston and piston rod into the lift cylinder. Release the clamp on the packing when the packing moves past the threads of the cylinder.

1. PISTON 2. SPECIAL TOOL OR BAND CLAMP TO INSTALL PACKING

21

Lift Cylinder Repair

4000 SRM 135

Chevron-Style Packing Installation in Packing Gland STEP 1.

Assemble the packing gland nut using new packing, O-ring, and backup ring.

1. PACKING ASSEMBLY 2. BACKUP RING 3. O-RING

4. PACKING RING MUST EXTEND 3 mm (1/8 in.)

BEYOND EDGE OF BUSHING.

STEP 2.

Assemble the gland nut using a new O-ring, backup ring, and inner seal.

NOTE: Install inner seal (if equipped).

STEP 3.

Install the bushing assembly and gland nut assembly in the rod.

22

Lift Cylinders for Vista® Masts

4000 SRM 135

STEP 4.

Install a new wiper ring and spring on the retainer. Install the retainer against the packing gland nut. Lightly hit the retainer to move against the internal threads in the cylinder shell. Use a spanner to tighten the retainer.

1. O-RING

Lift Cylinders for Vista® Masts DESCRIPTION All lift cylinders for Vista® masts are single-action hydraulic cylinders. The hydraulic force is applied only in one direction. When hydraulic oil enters one end of the lift cylinder, the hydraulic force extends the piston rod. When the force is removed, the weight of the carriage and inner mast causes the piston rod to retract.

The most common maintenance problem is the repair of oil leaks. If the bore of the shell of the lift cylinder is damaged and cannot be repaired, the lift cylinder must be replaced.

VISTA® two-stage, three-stage, and four-stage masts have two main lift cylinders. The free-lift mast has two main lift cylinders and a shorter free-lift cylinder. See Figure 17 and Figure 18.

Spacers are used in some cylinders to limit the stroke of the piston rod. Worn spacers must be replaced with the same size spacer.

The free-lift cylinder has a single-lip seal on the piston to prevent hydraulic oil leaks past the piston and

retainer. The piston rod is a smaller diameter than the piston.

During operation, some hydraulic oil will leak past the piston area to the rod end of the lift cylinder.

Small leaks are permitted if the internal leak rate of the hydraulic system is not greater than the specification. An internal check valve is installed in the piston of the free-lift cylinders. When the piston rod extends, the pressure increases more quickly on any oil in the rod end of the lift cylinder. The hydraulic oil transfers through the check valve to the piston end of the free-lift cylinder. This action prevents hydraulic damage to the single lip seal and the wiper ring. See Figure 19.

Lowering Control Valve A lowering control valve is installed in the hydraulic line to the bases of the lift cylinders. See Figure 20.

The lowering control valve permits easy entry of hydraulic oil into the cylinders, but gives a restriction when the rods retract. This restriction controls the maximum speed at which a load on the forks can be lowered. The lowering control valve prevents a load

23

Lift Cylinders for Vista® Masts on the forks from freely falling if a hydraulic hose breaks.

Figure 17. Vista® Masts Typical Lift Cylinders

24

4000 SRM 135

Lift Cylinders for Vista® Masts

4000 SRM 135 Legend for Figure 17 1.

2.

3.

4.

5.

SHELL BEARING PISTON PISTON ROD SNAP RING

6.

7.

8.

9.

10.

WASHER INNER PISTON CHECK VALVE O-RING SINGLE-LIP SEAL

11. BACK-UP RING 12. WIPER SEAL 13. RETAINER

1.

2.

3.

4.

5.

6.

SNAP RING INNER PISTON BEARING SINGLE-LIP SEAL BACK-UP RING SPACER

7.

8.

9.

10.

11.

ROD SHELL O-RING BACK-UP RING SEAL RING

12. RETAINER [TIGHTEN 340 to 410 N•m (250 to 300 lbf ft)] 13. WIPER SEAL 14. PISTON 15. 7.9 mm (0.31 in.) DIAMETER HOLE 16. WRENCH FLATS

Figure 18. Free-Lift Mast Main Lift Cylinder The lowering control valve includes the following parts: (1) valve body, (2) spring, (3) washer, (4) cylinder, (5) orifice sleeve, (6) plunger, and (7) main sleeve. The orifice sleeve position is controlled by oil flow. The plunger position is controlled by oil pressure and spring tension. During lifting, oil entering the lift cylinder goes through the center of the main sleeve to the large holes. The oil continues between the plunger and bore to move the orifice sleeve to the end of the plunger. The flange of the orifice sleeve is then aligned with the large part of the bore in the body. This alignment lets the oil flow around the orifice sleeve to the inlet port of the lift cylinder.

During the lowering operation, oil from the lift cylinder moves the orifice sleeve. The sleeve moves away from the larger area of the bore in the valve body. This movement makes a restriction to the oil flow. When the pressure increases, the plunger begins to move against the spring. The movement begins to close the openings of the large holes in the main sleeve. Additional pressure will push the plunger against the main sleeve to close the large holes completely. All the oil must go through the

small holes to the center of the main sleeve. This restriction permits the piston rod to lower only at a maximum controlled speed.

REMOVE NOTE: Remove the carriage before removing the lift cylinder. See the procedure described in the Masts section. If the mast assembly must be removed for repairs, then remove the lift cylinders when the mast assembly is disassembled. When only the lift cylinders must be removed for repairs, then remove the lift cylinders from the mast as described in the following paragraphs.

1. Clean the area around the hydraulic fittings for the lift cylinders. Disconnect the fittings at the lift cylinders and put caps on the open lines.

2. On the free-lift mast, remove the capscrews, washers, and cylinder clamp from the mount for the free-lift cylinder. Remove the free-lift cylinder.

3. Remove the snap rings and washers from the top of each main lift cylinder. Remove the cylinder 25

Lift Cylinders for Vista® Masts clamps near the top of each lift cylinder. Each cylinder clamp is fastened to the top crossmember of the inner mast by two capscrews and washers.

4. Support the cylinder. Connect a crane to the top of the inner mast using chains. Raise the inner mast from the outer mast approximately 30 cm (12 in.). Disengage the piston rod ends of lift cylinders from the top crossmember of the inner mast. Remove the lift cylinders from the mount plates at the bottom of the outer mast.

4000 SRM 135

DISASSEMBLE WARNING Use slings and a crane to handle and disassemble the lift cylinders of most lift trucks. Make sure that the crane and slings can lift the load correctly. See Table 1 for weight guide.

CAUTION Carefully disassemble and assemble the lift cylinders so that the piston rods and sliding surfaces are not damaged.

NOTE: Disassembly of the main lift cylinders and the free-lift cylinder is similar. All of the lift cylinders are disassembled from the rod end of the cylinder shell.

1. Loosen the retainer with a spanner. Disconnect the retainer from the shell.

2. Remove the protective cap from the inlet and slide the rod and piston assembly from the shell.

Drain the hydraulic oil into a container.

NOTE: To remove the retainer, the piston rod and piston assembly must be disassembled if the lift cylinder is the type shown in Figure 18. Use the following procedure: a. Put a round bar through the 7.9 mm (0.31 in.) hole in the piston. Hold the rod in a vise or clamp so that it does not turn. Use the round bar and turn the threaded piston from the piston rod. b. If an adhesive was used on the threaded rod and piston, heat the rod to a maximum of 170 to 225 C (300 to 400 F) to loosen the adhesive.

A. INSTALLED

B. NOT INSTALLED

1. PISTON AND ROD ASSEMBLY 2. CHECK VALVE 3. O-RING

4. INLET AND OUTLET PORT 5. SINGLE-LIP SEAL 6. O-RING 7. BACK-UP RING

Figure 19. Internal Check Valve and Single Lip Seal

26

3. Remove the retainer from the piston rod. Remove and discard the O-rings, seals, and bearings.

4. Remove the internal check valve from the base of the lift cylinder.

5. Clean all the parts. Check the sliding surfaces for damage. Repair or replace any damaged parts.

4000 SRM 135

Lift Cylinders for Vista® Masts

ASSEMBLE

3. Carefully push the piston and rod assembly into the shell. Release the clamp on the seal when the seal travels past the threads of the shell.

NOTE: • Lubricate all internal parts of the lift cylinder with hydraulic oil during assembly.

• Use new O-rings, seals, and bearings. Apply lubricant (hydraulic oil) during assembly. Packing lubricant (Part No. 186061) is also available.

• Make sure the single-lip seal assemblies are installed with the O-ring toward the base of the lift cylinder. (See Figure 19.)

CAUTION A difficult and important step in assembling lift cylinders is the correct installation of the seals. Most lift cylinder maintenance is caused by seal leaks.

1. Install the internal check valve, if installed.

Make sure the arrow on the internal check valve is toward the base of the piston.

2. Install the wear ring, single lip seal, and back-up ring onto the piston assembly. If a spacer sleeve is used, install it. Use shim material and a clamp as a guide to move the single-lip seal over the threads of the shell.

NOTE: When a main lift cylinder of the type shown in Figure 18 is assembled, use the following procedure: a. Install the seal ring and wiper ring into the retainer. Assemble the retainer onto the piston rod. b. Install the piston to the threaded part of the piston rod. Use a round bar through the hole in the piston and tighten the piston to the piston rod. Hold the piston rod in a vise or clamp by the two flats on the top end of the piston rod.

NOTE: Do not use an adhesive on the threads of the piston rod and piston.

4. Install the seal, O-ring, wear ring, and wiper ring in the retainer. If the wiper seal has a spring for a back-up ring, the spring must be toward the base of the lift cylinder.

5. Carefully install the retainer on the piston rod.

A. FREE FLOW B. LIFTING

C. RESTRICTED FLOW D. LOWERING

1. VALVE BODY 2. SPRING

3. WASHER 4. CYLINDER

5. ORIFICE SLEEVE 6. MAIN SLEEVE

Figure 20. Lowering Control Valve

27

Lift System Leak Check

4000 SRM 135

6. Engage the threads and tighten the retainer in the shell until it is tight. Use a correct spanner. Do not hit the retainer with a hammer and driver.

7. Install the lowering control valve. Make sure the special washer and the spring are installed correctly. A wrong installation can cause the load to lower too fast.

INSTALL Main Lift Cylinders

to the top crossmember of the outer mast with the capscrews and washers.

2. Install the lowering control valve on the outer mast. Connect the hydraulic lines and fittings between the lowering control valve and the lift cylinders.

3. Install the chain sheaves and brackets. Connect the lift chains to the chain anchors on the inner mast. Fasten wires between the ends of the lift chains so that they can be controlled during installation of the carriage.

4. Install the carriage. Connect the lift chains.

WARNING Connect slings and a crane to the top of the inner mast [and intermediate mast(s), if it is a 3-stage (4-stage) mast] using chains. If it is a 3-stage mast, make sure that all masts are fastened together. Make sure that the chains will not damage the sheaves, tubing or other parts of the mast. Make sure the crane and slings can lift the load correctly. See Table 1 for weight guide.

1. Install the main lift cylinders to the mounts at the base of the outer mast. Use a crane and lower the inner mast to engage the piston rods of the lift cylinders to the holes in the top crossmember of the inner mast. Install the washers and snap rings, or other locking device, at the top of the lift cylinders. Install the cylinder clamps near the top of each cylinder. Fasten the clamps, if used,

Free-Lift Cylinder 1. When the inner mast is lowered, install the freelift cylinder in the inner mast. A pin in the base of the lift cylinder will fit into the cylinder mount at the base of the inner mast. Fasten the upper end of the cylinder to the center crossmember with the bracket, washers, and capscrews. Install the chain sheave and brackets to the top of the free-lift piston rod.

2. Install the tubes and fittings at the bottom of the main lift cylinders. Install the lowering control valve. Install the hydraulic fitting in the end of the rod at the top of the left main cylinder. Install the tube between the top of the main lift cylinder and the base of the free-lift cylinder.

3. Install the carriage. Install the lift chain.

Lift System Leak Check WARNING Never allow anyone under a raised carriage.

Do not put any part of your body through the lift mechanism unless all parts of the mast are completely lowered and the engine is stopped.

Before making any repairs, use blocks and chains on the mast and carriage so that they can not move. Make sure the moving parts are attached to the parts that can not move.

Do not try to find hydraulic leaks by putting hydraulic components under pressure. Hydraulic oil can be injected into the body by pressure.

28

During the test procedures for the hydraulic system, fasten the load to the carriage with chains to prevent it from falling. Keep all personnel away from the lift truck during the tests.

1. Operate the hydraulic system. Put a capacity load on the forks and raise and lower the load several times. Lower the load and tilt the mast forward and backward several times. Check for leaks.

2. Raise the carriage and the load 1 m (3 ft). If the carriage lowers slowly with the control valve in a neutral position, there are leaks inside the hydraulic system. The maximum speed that the carriage is allowed to lower is 50 mm (2 in.) per

4000 SRM 135

Specifications

10 minutes when the hydraulic oil is 30 C (90 F).

If the oil temperature is 70 C (160 F), the maximum speed that the carriage can lower is 150 mm (6 in.) per 10 minutes.

3. Check the lift cylinder for internal leaks. Remove the load from the forks. Install a gate valve in the supply line between the main control valve and the mast. Put a capacity load on the forks again.

Raise the carriage 1 m (3 ft). Close the gate valve.

If the carriage or mast lower slowly, the seals in the lift cylinders have leaks.

4. If the carriage does not move, open the gate valve and check the movement again. If the carriage lowers when the gate valve is open, check for leaks in the hydraulic lines and fittings. If no leaks are found, the main control valve can have a defect. Remove the load from the forks.

NOTE: See the procedures in the mast repair sections for lift chain adjustments, mast adjustments, carriage adjustment, and header hose roller adjustment.

Specifications Table 2. Cylinder Retainer Torque Specifications and Weight Guide Rod Diameter

Typical Outer Retainer Torque Values

mm

N•m

in.

Lifting Mechanism

lbf ft

One-Stage Cylinders for Lift Trucks with Less than 7000 kg (15,000 lb) Capacity 57.2

2.25

373-441

275-325

63.5

2.50

203-271

150-200

69.9

2.75

373-441

275-325

76.2

3.00

407-475

300-350

81.3

3.20

407-475

300-350

88.9

3.50

475-452

350-400

101.6

4.00

407-475

300-350

114.3

4.50

610-678

450-500

Use crane and slings with at least 500 kg (1000 lb) capacity to lift the cylinder.

One-Stage Cylinders for Lift Trucks with More than 7000 kg (15,000 lb) Capacity 108.0

4.25

113.4

5.25

241.3

9.50

254.0

10.00

Tighten retainer or packing gland nut.

Oil leakage is not controlled by the torque on the retainer.

Use crane and slings with at least 1000 kg (2000 lb) capacity to lift the cylinder.

Use crane and slings with at least 2000 kg (4000 lb) capacity to lift the cylinder.

29

Troubleshooting

4000 SRM 135

Table 2. Cylinder Retainer Torque Specifications and Weight Guide (Continued) Rod Diameter

Typical Outer Retainer Torque Values

mm

N•m

in.

Lifting Mechanism

lbf ft

Two-Stage Cylinders for Lift Trucks with Less than 5000 kg (10,000 lb) Capacity 82.6

3.25

373-509

325-375

95.3

3.75

271-305

200-225

101.6

4.00

271-339

200-250

114.3

4.50

339-407

250-300

122.0

5.00

407-475

300-350

Use crane and slings with at least 500 kg (1000 lb) capacity to lift the cylinder.

Inner retainer torque value is 122 N•m (90 lbf ft).

Troubleshooting PROBLEM No movement of lift cylinders or tilt cylinders.

Slow movement of lift or tilt cylinders.

30

POSSIBLE CAUSE

PROCEDURE OR ACTION

Pilot line(s) to control valve are disconnected or leaking.

Tighten or connect fittings.

No oil or not enough oil in the hydraulic tank.

Fill tank. Check for leaks.

Relief valve(s) not set correctly.

Adjust or install new relief valve.

Hydraulic pump does not operate or has damage.

Repair or install new pump.

Remote control valve does not operate.

Check and repair valve.

No oil or not enough oil to lift or tilt cylinders.

Fill tank. Check for leaks.

Cylinders have internal or external leaks.

Repair leaks. Install new parts.

Relief valve is not set correctly.

Adjust or install new relief valve.

There is a restriction in a hydraulic line.

Remove restriction. parts.

Load is more than capacity.

Reduce load.

Install new

4000 SRM 135

PROBLEM Rough movement of the mast assembly.

Troubleshooting

POSSIBLE CAUSE

PROCEDURE OR ACTION

There is air in the hydraulic system.

Remove air. Check for loose connections or breaks in lines.

Lift cylinder(s) is damaged.

Repair or install new lift cylinder.

Mast weldments are damaged or not aligned.

Align weldments. Install new parts.

Mast weldments are not lubricated.

Lubricate correctly.

Load rollers or bearing blocks are damaged or not adjusted correctly.

Repair or adjust the parts.

Lift chains are damaged.

Replace lift chains.

31

TECHNICAL PUBLICATIONS 4000 SRM 135

2/01 (5/95)(9/87)(10/84)(3/83)(4/82)(7/81)(11/80) Printed in U.S.A.

INTRODUCTION GENERAL This section contains a MAINTENANCE SCHEDULE and the instructions for maintenance and inspection.

The MAINTENANCE SCHEDULE has time intervals for inspection, lubrication and maintenance. The time intervals are based on a normal operation. A normal operation is considered to be one eight hour shift per day in a relatively clean environment on an improved surface. Multiple shifts, dirty operating conditions, etc., will require a reduction in the recommended time periods in the Maintenance Schedule.

Some users have service personnel and facilities to do the items listed in the MAINTENANCE SCHEDULE. Service Manuals are available from your Hyster lift truck dealer to help users who do their own maintenance.

Your Hyster lift truck lift truck dealer has the personnel and equipment to do a complete program of inspection, lubrication and maintenance. Periodic maintenance will help your lift truck operate better over a longer period.

Put the lift truck on a level surface. Lower the platform and forks, apply the parking brake and turn the key switch to OFF. Open the access panels and check for leaks and conditions that are not normal. Clean any oil or other spills. Make sure that lint, dust, paper and other materials are removed from the compartments.

WARNING Do not make repairs or adjustments unless you have both authorization and training. Repairs and adjustments that are not correct can be made on a lift truck by people without authorization and training.

Repairs and adjustments that are not correct can make a dangerous operating condition.

Do not operate a lift truck that needs repairs. Report the need for repairs immediately. If repair is necessary, put a “DO NOT OPERATE” tag in the operator’s area. Remove the key from the key switch.

HOW TO MOVE A DISABLED LIFT TRUCK

WARNING Use extra care when moving a lift truck during the following conditions: a. Brakes do not operate correctly b. Steering does not operate correctly c. Tires are damaged d. Traction conditions are bad e. The lift truck must be towed on a steep grade.

If there is no electrical power, there is no steering and the brake will be applied. Do NOT tow the lift truck if there is no power. Poor traction can cause the disabled lift truck or towing vehicle to slide. Steep grades will require additional brake force to stop the lift truck.

Never carry a disabled lift truck unless the lift truck MUST be moved and can not be towed. The lift truck used to lift the disabled lift truck MUST have a rated capacity equal to or greater than the weight of the disabled lift truck. The capacity must be for a load center equal to half the width of the disabled lift truck. See the nameplate on the disabled lift truck for the approximate total weight. The forks must extend the full width of the disabled lift truck. Center the weight of the disabled lift truck on the forks and be careful not to damage the under side of the disabled lift truck. Tilt the mast back and travel slowly.

CAUTION Do NOT tow the lift truck by fastening a towing device to the attachment or base arms. Make sure the guidance sensors are not damaged when connecting a chain to the lift truck.

How To Tow The Lift Truck 1. If the lift truck must be towed, the operator must be on the lift truck to release the brake and steer the lift truck.

2. Tow the lift truck slowly.

3. Raise the platform approximately 30 cm (12 inches) from the surface. Install a chain to prevent the platform and mast channels from moving.

4. If another lift truck that has the drive wheels near the forks is used to tow the disabled lift truck, that lift truck

1

must have weight added to the forks. The total weight of the lift truck and load must be equal or greater than the weight of the disabled lift truck. Install a load of approximately half the maximum capacity on the forks of the lift truck that is used for towing. This load will increase the traction of the lift truck. Keep the load on the forks lowered as much as possible. If the lift truck used for towing has a master drive unit or drive unit similar to the R40E/EA/EF/ES, do NOT add weight to the forks. Additional weight on the forks will DECREASE the traction of the drive wheel(s). Make sure that the lift truck has a total weight equal to or greater than the weight of the disabled lift truck.

5. Make sure the tow chain has the capacity to tow the weight. Carefully fasten the tow chain to the drive unit end of the lift truck. Make sure the chain is fastened so that the chain will not cause damage to either lift truck.

CAUTION Make sure the sensors are not damaged on trucks that have wire guidance.

2. Use a special low clearance hydraulic jack, crane or another lift truck to raise the drive tire. Make sure that the jack, crane or other lift truck has the correct minimum capacity rating. The capacity must equal at least 2/3 the weight of the lift truck including the battery. See the nameplate.

3. Raise the lift truck only enough to suspend the drive tire. Install additional blocks under the frame near the drive tire.

How To Raise Load Wheels (See FIGURE 1.)

1. Put blocks on both sides (front and back) of the drive tire to prevent movement of the lift truck.

HOW TO PUT A LIFT TRUCK ON BLOCKS

WARNING The lift truck must be put on blocks for some types of maintenance and repair. The removal of the following assemblies will cause large changes in the center of gravity: mast, battery and master drive unit.

Do NOT put the lift truck on blocks if the surface is not solid, even and level. Make sure that any blocks used to support the lift truck are solid, one–piece units. Put a block in front and back of the tires touching the ground to prevent movement of the lift truck.

Do not raise the lift truck by attaching an overhead crane to the overhead guard or areas of the mast that can be damaged. Some of these components and other lift points are not designed to support the weight of the lift truck. The lift truck can be damaged or it can fall on someone causing serious injury. Attach the chain or sling to a support structure of the lift truck frame.

How To Raise Drive Tire (See FIGURE 1.)

1. Put blocks on each side (front and back) of the load wheels to prevent movement of the lift truck.

2

CAUTION Make sure the sensors are not damaged on trucks that have wire guidance.

WARNING Never raise the base arms any higher than necessary to change the load wheels. Always raise both base arms at the same time. Raising the base arms too high can make the lift truck tip over and cause damage or possible injury.

2. Use a hydraulic jack, crane or another lift truck to lift the base arms. Make sure that the jack, crane or other lift truck has a capacity equal to at least half the weight of the lift truck including the battery.

3. Put blocks under the base arm at the rear of the load wheel to support the lift truck.

CAUTION For correct operation of the wire guidance system, both load wheels must always be replaced at the same time. The load wheels must have the same diameter within 1 mm (0.039 in).

R30E/EA/EF

R30ES

12292

DRIVE/STEER WHEEL

LOAD WHEEL

FIGURE 1. PUT THE LIFT TRUCK ON BLOCKS

MAINTENANCE SCHEDULE 23

9

3

22

6

4

1 11 20

2

13

7 3 17 19

8

4 24

12296

10

3

22

5 21

15 16

12 18

13

R30E/EA/EF SHOWN R30ES SIMILAR

FIGURE 2. MAINTENANCE POINTS

3

TABLE 1. MAINTENANCE SCHEDULE (Item No. Reference Figure 2) ITEM NO. 1

350 2000 8 Hr/ Hr/ Hr/ 1 day 2 mo 1 yr

ITEM

PROCEDURE OR QUANTITY

SPECIFICATION

3

HYDRAULIC OIL (Full Mark) R30E/EA R30EF R30ES OIL LEAKS BATTERY PANELS – LATCHES DRIVE TIRE AND WHEELS

X X X

4

FORKS

X

Check Condition

See BATTERY SPECIFICATIONS See Parts Manual See Parts Manual

5

LIFT CHAINS

X

Check Condition

See Parts Manual

6

MAST AND PLATFORM

X

Check Condition

7

BRAKE

X

Check Operation

8

GAUGES, HORN, FUSES

X

Check Operation

9

STEERING

X,L

Check Operation

Multi–Purpose Grease3

2

C1 C1 C1

X X X 2

L

30 litre (7.9 gal) 36 litre (9.5 gal) 14.6 litre (3.9 gal) Check For Leaks Check Level Check Operation Check Condition

–18°C to 38°C (0°F to 100°F) SAE 10W API SC/CC

Hold On 5% Grade

10

DIRECTION/SPEED CONTROL

Check Operation

MIL–G–7711A or equivalent

11 13 12

HYDRAULIC TANK BREATHER HYDRAULIC PUMP COUPLING CONTACTOR TIPS

X L X

Clean Or Replace Clean And Soak Check Condition

See Parts Manual Hyster Part No. 351333 See Parts Manual

13

MOTOR BRUSHES

X

Check Condition

See Parts Manual

X

Replace if Necessary

See Parts Manual

6 15 4 5 16

SAFETY LABELS MAST AND PLATFORM ROLLERS FORK PIN AND GUIDES LIFT CHAINS AND SHEAVES SLIDING SURFACES

L L X,L L

As Required As Required As Required As Required

Multi–Purpose Grease3 Multi–Purpose Grease3 SAE 20 Oil or P/N 171550 Multi–Purpose Grease3

17

WHEEL NUT TORQUE

X

18

MASTER DRIVE UNIT (R30ES) (R30E/EA/EF)

X X

19

X

Tighten if Required

136 N.m (100 lbf ft)

C C

2.5 litre (2.6 qt) 3.8 litre (1 gal)

MIL–L–2105 B, AGL–5 SAE 80W–90 or 85W–140

L C C

As Required 325 ml (11 oz.)

1 ea.

Multi–Purpose Grease3

20

STEERING CHAIN STEERING GEAR HOUSING HYDRAULIC FILTER

Hyster Part No. 347031 See Parts Manual

21 22 23

ELECTRIC. CABLE SHEAVES BASE ARM BEARINGS PALLET CLAMP

L L L

As Required As Required As Required

Multi–Purpose Grease3 Multi–Purpose Grease3 Multi–Purpose Grease3

24

EMERGENCY STOP KNOB LIMIT SWITCH ROLLERS MISC.

L L

Check Operation As Required As Required

Multi–Purpose Grease3 Hyster Part No. 347031

X

X = Check C = Change L = Lubricate Change oil after first 250 hours. Change oil every 1000 hours or six months with corrosion/freezer option.

Equalization Charge approximately each month but not more than each week.

3 Multi–Purpose Grease with 2–4% Molybdenum Disulfide.

1 2

NOTE: Never use steam to clean electrical parts.

4

MAINTENANCE PROCEDURES EVERY 8 HOURS OR DAILY WARNING Do NOT operate a lift truck that needs repairs. Report the need for repairs immediately. If repair is necessary, put a “DO NOT OPERATE” tag in the operator’s area. Remove the key from the key switch.

HOW TO MAKE CHECKS WITH KEY SWITCH OFF Hydraulic System (See FIGURE 3.)

WARNING

the three nuts that fasten the plate to the top of the tank.

Carefully lift the plate assembly, tube and filter element while keeping the tube vertical. The filter element is held on the bottom of the tube by a grommet as shown in FIGURE 7. Install the replacement element on the tube, install the plate assembly and connect the hose to the fitting.

NOTE: If the filter element slips off the tube during removal or installation, use the end of the tube to move the element into the correct position to insert the tube in the element.

Inspect the hydraulic system for leaks and damaged or loose components.

Do not permit the hot hydraulic oil to touch the skin and cause a burn. When the hydraulic oil is at operating temperature, it is HOT.

1

5

2

3

1

CAUTION 4

Do not permit dirt to enter the hydraulic system when the filter is changed.

Never operate the hydraulic pump without oil in the hydraulic system. The operation of the hydraulic pump without oil will damage the pump.

Check the hydraulic oil level at the sight gauge when the oil is at operating temperature. The platform must be lowered and the key switch must be OFF. If the oil level is not visible at the sight gauge, the oil level is above or below the sight gauge. open the door of the hydraulic compartment to check for the correct level and to fill the tank if necessary. If too much hydraulic oil is added, the oil will leak from the breather during operation. Clean the breather and fill cap by flushing with solvent. Install and tighten the fill cap.

To drain the oil, put the lift truck on a level surface.

Completely lower the mast and the forks. Use a container with a 36 litre (9.5 gal) capacity near the supply hose of the hydraulic tank to hold the oil. The R30EF and R30ES units need a container with a capacity of 36 litre (9.5 gal). Turn the key switch to the OFF position and disconnect the battery.

Replace the element every 2000 hours or yearly with each oil change. To replace the element, remove and plug the hose at the fitting near the breather. Remove

4 5 3 6

1.

2.

3.

4.

5.

6.

7.

8.

FILL/BREATHER PLATE ASSEMBLY HOSE CONNECTOR SIGHT GAUGE HYDRAULIC TANK TUBE 8 FILTER ELEMENT GROMMET

7

12293

R30E/EA standard hydraulic tank shown.

R30EF tank is larger. R30ES tank is smaller.

FIGURE 3. HYDRAULIC CHECKS Battery

WARNING Do not put tools on the battery. Tools on the battery can cause a short circuit and possible damage or injury.

5

The acid in the electrolyte can cause injury. If the electrolyte leaks, use water to flush the area. Make the acid neutral with a solution of sodium bicarbonate (soda) . Acid in the eyes must be immediately flushed with water.

Check the level of the electrolyte daily on a minimum of one cell. Add only distilled water, as necessary, to all cells if the cell is low. The correct level is half–way between the top of the plates and the bottom of the fill hole. To check and add water to the cells, the battery must be out of the battery compartment.

Dealer for the correct spacers. The correct battery is in BATTERY SPECIFICATIONS at the end of this section. Check that each battery compartment panel fits correctly and is not bent. On R30E/EA/EF units, check that each panel latch engages the panel bracket correctly and that the welds on the bracket are not broken.

Each latch must be free to operate and remain in the Up position when the notch is engaged.

Mast, Platform, Forks And Lift Chains (See FIGURE 4. and FIGURE 5.)

WARNING

WARNING Do NOT put hands, arms, feet or legs between the battery and a solid object. Batteries are very heavy and can cause an injury.

The lift truck and battery stand must be on a level surface to remove the battery.

NEVER work under a raised platform or forks.

Lower the platform or use chains on the mast weldments and platform so that they can not move. When chains are used, make sure the moving parts are fastened to a part that can not move.

Remove the battery as described in CHANGING THE BATTERY in this section. Check the battery case, connector and cables for damage, cracks or breaks. See the battery dealer in your area to repair any damage. Keep the battery case, and the battery compartment clean and painted. Leaks and corrosion from the battery can cause a malfunction in the electric controls of the lift truck. Use a water and soda solution to clean the battery and the battery compartment. Keep the top of the battery clean, dry and free of corrosion.

1

7

5

2 6

4

3

Check that the correct spacer is installed across the mast side of the battery compartment. The spacer must allow the battery to move not more than 13 mm (0.5 in) toward the front or rear of the compartment. Check that the battery cannot move more than 13 mm (0.5 in) across the width of the lift truck. If the battery can move more than the maximum amount, make sure the battery is the correct weight and the correct spacers are installed for that battery. See your Hyster Lift Truck

6705

1.

2.

3.

4.

WORN PIN CRACKS EDGE WEAR HOLE WEAR

5. LOOSE LEAVES 6. DAMAGED PIN 7. RUST

FIGURE 4. INSPECT THE LIFT CHAINS AND CABLES

3 2

2

5 2

4 1 6706

1. TIP ALIGNMENT

2. CRACKS

3. FORK PIN DAMAGE

4. NEWER STYLE

FIGURE 5. HOW TO INSPECT THE FORKS

6

5. OLDER STYLE

WARNING Do not try to correct alignment of the fork tips by bending the forks. Use shims to align the fork tips.

Replace damaged forks.

Never repair damaged forks by heating or welding.

Forks are made of special steel using special procedures. Replace damaged forks. Always replace forks in pairs.

1. Inspect the welds on the mast and platform for cracks. Make sure that the nuts and bolts are tightened.

2. Inspect the channels for wear in the areas where the rollers travel. Inspect the rollers for wear or damage.

3. Check all lift chains for the correct lubrication. Lubricate the lift chains using the oil specified in the MAINTENANCE SCHEDULE in this section.

4. Inspect the lift chains for cracks or broken links and pins. See FIGURE 4.

Pallet Clamp Check for correct operation of the pallet clamp. Put an empty pallet on the forks. With the forks raised so that the pallet is supported by the forks, stand on the corners of the pallet farthest from the operator’s platform.

Some movement may occur, but the board under the opposite fork must not raise enough to contact the fork.

Tire, Wheels and Caster (See FIGURE 6.)

Inspect the caster (R30EF only), drive tire and load wheels for damage. Inspect the tread and remove any objects that will cause damage. See FIGURE 6. Inspect the wheels and caster for loose or missing parts. Remove any wire, strapping, or other material wound around the axles or caster.

1 2

5. Inspect the chain anchors and pins for cracks or damage.

6. Make sure the lift chains are adjusted so that they have equal tension. Check tension by pulling horizontally on both chains and checking that they move the same amount. If the chains need repair or adjustment, it must be done by authorized personnel.

2

7. Check that the fork tips are aligned within 13 mm (0.5 in) of each other. See item 1 of FIGURE 5. Add or remove shims for alignment.

8. Inspect forks for cracks and wear.

9. Replace any damaged or broken parts that are used to keep the forks locked in position.

Tether Line And Belt 1. Inspect the tether line for wear, cuts or damage. Inspect the clips for cracks and proper operation.

WARNING The tether line is specially made to lessen the shock during a fall. Do not substitute other types of rope.

2. Inspect the belt for cracks, cuts or wear. The operator must fasten the belt snugly with the “D” ring in the center of the back.

11402

1. MAKE SMOOTH EDGES 2. REMOVE NAILS, GLASS AND ALL METAL

FIGURE 6. INSPECTING THE TIRE AND WHEELS Make sure the wheel nuts are tightened to the correct torque value. Tighten the nuts in a cross pattern to the correct torque value shown in the Maintenance Schedule table.

CAUTION If the wheels have been removed and installed, check all wheel nuts after 2 to 5 hours of operation. Tighten the nuts in a cross pattern to the correct torque value shown in the MAINTENANCE SCHEDULE table.

When the nuts stay tight after eight hours, the inter-

7

val for checking the torque can be extended to 350 hours.

HOW TO MAKE CHECKS WITH THE KEY SWITCH ON WARNING Make sure the area around the lift truck is clear before moving the lift truck or checking for correct operation. Be careful when making the checks.

Gauges, Lights, Horn And Fuses (See FIGURE 7. and Table 1) NOTE: None of the electrical controls will operate until the power disconnect circuit is energized by the key switch.

Check that all the instruments and controls operate as described in OPERATING MANUAL. Check the operation of the gauges and horn. The key switch must be in the ON position to operate the horn. The key switch must be ON and the foot switch depressed for the hour

meter to operate. The battery meter operates whenever a charged battery is connected.

The battery meter correctly indicates the condition of the battery. If the battery meter needle is in the red area or the light (lift interrupt) is ON, charge the battery.

There must be a current flow from the battery before the indicator for the lift interrupt will be reset and indicate correctly. Normal operation, after connecting a charged battery, will reset the indicator.

There is a 15 amp control fuse under the instrument panel. There can also be a 15 amp fuse for the spot light and fan. There is also a 35 amp fuse near the steer motor contactor in the motor compartment. There are two power fuses in the electrical compartment. The power fuses have the following ratings: Traction Motor – 300 amp Hydraulic Pump Motor – 500 amp Check that the fuses are the correct size and are not burned. Some types of fuses must be checked with an ohmmeter. If any of the fuses are bad, disconnect the battery before replacing the fuse.

NOTE: Location of Guidance Button and Light can be different than shown.

4 7 9 5 8 6 10

15 12

11 12

1

OLDER UNIT (EXCEPT R30ES)

3

11

14

14 16 NEWER UNITS (EXCEPT R30ES) 13 18

17

2 1. STEERING CONTROL 2. STEER TIRE 1 POSITION INDICATORS 3. GUIDANCE BUTTON AND LIGHT 4. FAN SWITCH BUTTON 5. SPOT LIGHT SWITCH BUTTON 6. BATTERY INDICATOR 7. HOUR METER 8. EMERGENCY STOP KNOB 9. KEY SWITCH

12294

R30ES ONLY 10.

11.

12.

13.

14.

15.

16.

17.

18.

DIRECTION/SPEED CONTROL 11 HORN SWITCH BUTTON FAST LIFT SWITCH BUTTON SLOW LIFT/LOWER ROCKER SWITCH FAST LOWER SWITCH BUTTON SLOW LIFT SWITCH BUTTON SLOW LOWER SWITCH BUTTON LIFT SWITCH LOWER SWITCH

FIGURE 7. INSTRUMENTS AND CONTROLS

8

Switches And Direction/Speed Control Check that the Direction/Speed control and the switches for Lift and Lower operate as described in Table 1 of the OPERATING MANUAL. Check that the foot switch and Direction/Speed control operates as described in the Operating Procedures section of the OPERATING MANUAL. Check the operation of the Emergency Stop knob. The location of the knob is shown in FIGURE 7. Push the knob with the key switch ON and the foot switch depressed. All electrical circuits must NOT operate.

Move the key to the OFF, START and ON positions to reset the power disconnect circuit.

Lift System Operation

WARNING Lower the lift mechanism completely. Never allow anyone under a raised platform or forks. Do not put any part of your body in or through the lift mechanism unless all parts of the mast and platform are completely lowered and the key switch is in the OFF position. Remove the key.

raise smoothly. Lower the platform and forks. All moving components must lower smoothly.

5. Check that the top of the forks are 70 to 83 mm (2.75 to 3.25 inches) above the floor for the R30E units.

Check that the forks are 159 to 171 mm (6.25 to 6.75 in) above the floor for the R30EA, R30EF and R30ES units. If the clearance is not correct, the chain anchors must be adjusted.

6. Check the operation of the limit switches on the mast. The maximum travel speed must be slower when the platform is above 910 mm (24 in). The R30E units must not move when the platform is above 3810 mm (150 in) unless the lift truck has the Override function and the Override button is depressed. The R30EA, R30EF and R30ES units will move when the platform is above 3810 mm (150 in) if the steering system is within 7° of straight travel.

7. If necessary, have the lift truck checked and adjusted by authorized service personnel.

Brake

Do not try to find hydraulic leaks by putting hands on hydraulic components under pressure. Hydraulic oil can be injected into the body by pressure.

Check the operation of the brake. The brake is applied as the operator’s foot is removed from the foot switch.

The brake must not let the lift truck move if parked on an incline. The brake, when in good condition and correctly adjusted, will hold the lift truck with a capacity load on a 5% grade [a slope of 0.5 metre in 10 metres (a slope of 0.5 ft in 10 ft)]. If the brake does not hold the lift truck on the grade, the brake needs to be checked by authorized service personnel. Refer to the procedures for the BRAKE in EVERY 2000 HOURS OR YEARLY of this section.

1. Check for leaks in the hydraulic system. Check the condition of the hydraulic hoses and tubes.

Steering System

Before making any repairs, completely lower the platform or use chains on the mast weldments and platform so that they can not move. Make sure the moving parts are fastened to the parts that can not move.

2. Slowly raise and lower the forks and the platform several times without a load. All moving components must raise and lower smoothly.

3. The platform and the forks must lower completely.

4. Raise the platform one metre (three feet), with a capacity load. The inner weldment and platform must

WARNING There is NO steering if there is no electrical power.

To prevent injury or damage, make sure the electric power steering is operating correctly before moving the lift truck.

Check that the steering system operates smoothly and gives good steering control.

9

EVERY 350 HOURS OR TWO MONTHS Do these procedures in addition to the 8 hour checks.

HYDRAULIC TANK BREATHER (See FIGURE 3.)

The fill cap and breather assembly are in the hydraulic compartment at the top of the hydraulic tank. Remove the fill cap assembly from the hydraulic tank and clean the filter material of the breather in solvent. Replace the fill cap and breather assembly if air will not flow through it easily.

ELECTRICAL INSPECTION WARNING Disconnect the battery connector before making any inspections or repairs. Personal injury or equipment and tool damage can occur if the battery is not disconnected.

Do not touch the terminals of capacitor C1 of the traction or lift control circuits. The charge on the capacitors can cause electrical shock and personal injury. Use an insulated screwdriver or jumper wire to make a short–circuit across the capacitor terminals to discharge each capacitor. This will discharge the capacitors to prevent electrical shocks.

Contactors The contact surfaces of the contactor are a silver alloy over a copper base. In normal operation, the contact surfaces become a dark color and rough. Cleaning is not necessary. Do not use a file or emery cloth on the contacts. Replace the contacts when the surface is worn to the base material. Always replace the contacts in sets (two pairs). If necessary, disassemble the contactor to inspect the contacts. See the section EV–100 MOTOR CONTROLLER – REPAIR, 2200 SRM 288, for the correct replacement procedures of contactors on the R30E/EA/EF units. See the section CURTIS TRANSISTOR MOTOR CONTROLLER, 2200 SRM 411, for the correct replacement procedures of contactors on the R30ES units.

CAUTION Low battery voltage makes motors use high currents for a longer time to do the same work. These currents

10

can damage motors and weld contactor contacts.

Never try to repair contactor contacts that are welded. Always replace welded contacts. Do not operate the lift truck using a battery that has a specific gravity of 1.130 or less.

WARNING If the lift truck has been operated using a low battery or deenergized with the power disconnect circuit, inspect for welded contacts BEFORE connecting a charged battery. The Power Disconnect circuit will not reset and lift truck operation cannot be controlled if the contacts are welded.

Open the electrical compartment for access to the contactors.

Motor Brushes (See FIGURE 8.)

CAUTION Low battery voltage makes motors use high currents for a longer time to do the same work. These currents can damage motors and contactor contacts. Do not operate the lift truck using a battery that has a specific gravity of 1.130 or less.

WARNING Disconnect the battery before making any checks on the motors. Personal injury or equipment and tool damage can occur if the battery is not disconnected.

Open the front compartment doors for access to the motors.

To check the motor brushes, disconnect the battery and get access to the motor. Check motor brushes using the following procedure: a. Visually inspect the commutator and brushes every 350 hours on all electric motors. Remove the brush cover near one end of the motor. Move the brush spring to remove a brush from the holder. Pull the brush from the holder. Make sure the surface of the commutator is good and the operation of the motor is correct. All motor brushes must be replaced before they damage the surface of the commutator. Replace brushes

before they are worn to the values shown in TABLE 2.

NOTE: It can be necessary to remove the contactor from the steering pump motor for access to the brushes. b. Inspect the brush holders for burns or damage.

Make sure the brush holder is fastened tightly to the mounts. Make sure the brushes will move freely and smoothly in the brush holders and do not have wire breaks. c. Check the brush springs for damage from heat (color changes) and corrosion. Replace a damaged brush spring. d. Use dry compressed air under low pressure to remove any brush dust.

NOTE: See the section DC MOTOR MAINTENANCE, 620 SRM 294, for additional information for repair of the commutator and brushes.

SAFETY LABELS Safety labels are installed on the lift truck to give information about possible hazards. It is important that all

safety labels are installed on the lift truck and can be read.

WARNING If labels that have warnings or instructions are damaged, they must be replaced immediately.

Check that all safety labels are installed in the correct location on the lift truck. Make sure all labels are not damaged and that they can be read. If necessary, see the FRAME section or the PARTS MANUAL for your lift truck for the correct location of the labels.

See the FRAME section for the installation procedures.

MAST WARNING Never work under a raised platform or forks. Lower the platform and the forks or use chains on the mast weldments and carriage so that they can not move.

When chains are used, make sure the moving parts are fastened to a part that can not move.

1. Inspect the surfaces in the channels where the load rollers travel. A scraper and solvent can be used to clean dirt from the mast channels.

4

4 4

1

2

3

1.

2.

3.

4.

TRACTION MOTORS LIFT PUMP MOTOR STEERING GEARMOTOR ACCESS COVER

FIGURE 8. INSPECT THE MOTOR BRUSHES

11

TABLE 2. MOTOR BRUSH MINIMUM DIMENSIONS MOTOR

DIMENSION “A”

TRACTION MOTOR

16 mm (0.63 in.)

LIFT PUMP MOTOR

14 mm (0.55 in.)

STEERING GEARMOTOR

7 mm (0.25 in.)

1 A* = MINIMUM DIMENSION SHORTEST SIDE 1. TAPERED END (SPRING) 2. WEAR END

A

2

CAUTION Be careful when steam or high pressure water is used to clean the mast channels. Do NOT permit the steam or water to be used on the load rollers, sheaves, or lift chains. The steam or water will damage the bearings in the load rollers and sheaves, and cause corrosion in the lift chains.

2. Apply a thin layer of multi–purpose grease to the surfaces in the channels of the free–lift mast where the load rollers travel. Apply the grease to both the roller surfaces and the thrust surfaces in the mast.

NOTE: The mast and platform load rollers have sealed bearings that do not need additional lubrication.

3. Use multi–purpose grease to lubricate all sliding surfaces and the chain sheaves at the top of the masts.

4. Lubricate the lift chains using the oil specified in the MAINTENANCE SCHEDULE.

CHECK FOR LEAKS IN THE LIFT SYSTEM Check the hydraulic system for internal leaks after every 350 hours of operation.

WARNING Never allow anyone under a raised platform or forks. Do not put any part of your body in or through either lift mechanism unless all parts of the mast and carriage are completely lowered and the key is in the OFF position.

Before making any repairs, use chains on the mast weldments and carriage so that they can not move.

Make sure the moving parts are fastened to the parts that can not move.

Do not try to find hydraulic leaks by putting your hand on hydraulic components under pressure. Hydraulic oil can be injected into the body by the pressure.

12

During test procedures for the hydraulic system, fasten the load to the carriage with chains to prevent it from falling. Keep all personnel away from the lift truck during the tests.

Check The Lift Cylinders For Leaks NOTE: R30ES units have only one lifting speed and one lowering speed. They do not have a free–lift cylinder.

1. Operate the hydraulic system. Put a capacity load on the forks and raise and lower the load several times.

Operate both the slow–lift and fast–lift functions.

Check for leaks.

2. Raise the carriage and load one metre (3 ft). If the carriage slowly lowers when the control valve is in the Neutral position, there are leaks inside the hydraulic system. Check both the slow–lift and fast– lift systems.

The maximum speed that the forks can slowly lower when there are internal leaks is 50 mm (2 in) per 10 minutes. This maximum leak rate is specified for an oil temperature of 30°C (90°F). If the temperature of the hydraulic oil is 70°C (160°F), the specification increases to 150 mm (6 in) per 10 minutes.

3. If there are leaks in the hydraulic system, check the lift cylinders for internal leaks.

R30E/EA/EF units only. Remove the load and fully lower the forks. Install a gate valve in the supply line between the main control valve and the free–lift cylinder. Put a capacity load on the forks again. Raise the forks 50 cm (1–1/2 ft). Close the gate valve. If the forks slowly lower, the seals in the free–lift cylinder have leaks.

4. Completely lower the forks. Install a gate valve at the base of each main lift cylinder. Raise the load.

Close the gate valve at the base of one main lift cylinder. Push a Lower rocker switch to lower the mast. If the load slowly lowers, the seals in one main cylinder leak. The cylinder that has the leak is the cylinder with

the closed valve. Open the gate valve of the first main cylinder and close the gate valve at the base of the other main cylinder. Repeat the check for the other main lift cylinder.

LIFT CHAINS (See FIGURE 4. and FIGURE 9.)

5. If the load does not lower with either gate valve closed, open the gate valve and check the movement again. If the load lowers when the gate valve is open, check for leaks in the hydraulic lines and fittings. If no leaks are found, the lowering valve can have a malfunction. Remove the load from the forks.

If a section of chain is 3% longer than a similar section of new chain, replace the worn chain.

6. Completely lower the forks. Remove all gate valves and connect the hydraulic lines to the cylinders.

Lubricate the lift chains using the oil specified in the MAINTENANCE SCHEDULE in this section.

If a chain scale is available, check the lift chains as shown in FIGURE 9. If a chain scale is not available, measure 20 links of chain. Compare the lengths with the chart in FIGURE 9. Replace the chain if the length of 20 links of the worn section is more than the maximum wear limit.

1

9488

NOTE: The instructions for measuring chain wear are shown on the Chain Wear Scale.

1. CHAIN WEAR SCALE

5122

FIGURE 9. INSPECT THE LIFT CHAINS

WARNING Do not repair a worn lift chain. Replace a worn lift chain with a new lift chain. Both chains must be replaced if one lift chain needs replacing.

FORKS (See FIGURE 5.)

WARNING Never repair damaged forks. Do not heat, weld, or bend forks. Replace damaged forks.

Check the attachment points of the forks with a penetrant or magnetic particle inspection.

13

EVERY 2000 HOURS OR YEARLY Do these procedures in addition to the 8 hour and the 350 hour checks.

MASTER DRIVE UNIT (See FIGURE 10.)

Change the oil every 2000 hours or each year. Drain the oil when it is warm by removing the drain plug. Use a container to keep oil off the floor. Flush the breather using solvent each time the oil is replaced. On older units (MDU Part Number 338600), clean and fill the outer axle bearing with Shell Alvania R3 grease.

STEERING CHAIN Lubricate the steering chain with the grease shown in the MAINTENANCE SCHEDULE in this section.

Lubricate the bearings of the load wheels with the grease shown in the MAINTENANCE SCHEDULE. The load wheels must be removed for lubricating as described in GENERAL PROCEDURES if there are no grease fittings.

NOTE: On units that have the freezer and corrosion option, add grease through each of the grease fittings.

HOW TO CHANGE THE HYDRAULIC OIL AND FILTER (See FIGURE 11.)

WHEELS AND BEARINGS Check that the drive wheel nuts are tightened to the value shown in the MAINTENANCE SCHEDULE in this section.

WARNING The hydraulic oil is HOT at operating temperature.

Do not permit the hot hydraulic oil to touch the skin and cause a burn.

Put the lift truck on a level surface. Completely lower the mast and the forks. Put a container with a capacity large enough to hold the quantity of oil shown in the PERIODIC MAINTENANCE table for your unit. Put the container near the supply hose of the hydraulic tank. Turn the key switch to the OFF position and disconnect the battery.

1

2

3

11390

1. MASTER DRIVE UNIT 2. FILL PLUG 3. DRAIN PLUG

FIGURE 10. MASTER DRIVE UNIT Remove each load wheel and the bearings as described in GENERAL PROCEDURES in this section. Check each bearing for smooth operation. If the operation is smooth, clean and fill each bearing with multi–purpose grease. If the bearing operation is not smooth, replace

14

the bearing. Install the bearings with the seal toward the outside of the load wheel. Install the load wheels as described in GENERAL PROCEDURES in this section.

Replace the element every 2000 hours or yearly with each oil change. To replace the element, remove and plug the hose at the fitting near the breather. Remove the three nuts that fasten the plate to the top of the tank.

Carefully lift the plate assembly, tube and filter element while keeping the tube vertical. The filter element is held on the bottom of the tube by a grommet as shown in FIGURE 11. Install the replacement element on the tube, install the plate assembly and connect the hose to the fitting.

Raise the front of the lift truck as described in HOW TO PUT A LIFT TRUCK ON BLOCKS in this section. There is no drain plug in this hydraulic tank. The hydraulic tank is drained at the supply hose. Open the hydraulic compartment door for access to the tube end of the supply hose. Use a shallow pan with a capacity of approximately 30 litre (7.9 gal) for the oil. Put the pan under the end of the hose. Disconnect the hose from the

tube and drain the oil. Connect the hose to the tube and tighten the hose clamp. Remove the fill cap and fill the tank so that the oil level is at the center of the sight gauge. Fill the hydraulic tank with the oil shown in the MAINTENANCE SCHEDULE in this section. See HOW TO MAKE CHECKS WITH THE KEY SWITCH OFF for the correct filling procedure.

To replace the filter, remove and plug the hose at the fitting near the breather. Remove the three nuts that fasten the plate to the top of the tank. Carefully lift the plate assembly, tube and filter while keeping the tube vertical. The filter is held on the bottom of the tube by a grommet as shown in FIGURE 11. Install the replacement filter on the tube, install the plate assembly and connect the hose on the fitting.

NOTE: If the filter slips off the tube during removal or installation, use the end of the tube to move the filter into position and insert the tube in the filter element.

Check the hydraulic system for leaks and damage or loose components. Close the hydraulic compartment door.

5

1

2

3

1

personnel. The brake, when in good condition and correctly adjusted, will hold the lift truck with a capacity load on a 5% grade [a slope of 0.5 meter in 10 meters (a slope of 0.5 ft in 10 ft)]. See the section THE ELECTRIC BRAKE, 1800 SRM 305, to check or repair the brake or to replace the friction disc.

3 4 2

6 7

5 7

1

12350

0.33 to 0.38 mm (0.013 to 0.015 in) 1. ARMATURE PLATE 2. RETURN SPRING (3) 3. CAPSCREW (3) 4. SPRING WASHER (3) 5. BACK PLATE

10 6.

7.

8.

9.

10.

9

8

HUB FRICTION DISC SPRING (12) MAGNET ASSEMBLY BORE, CAPSCREW

FIGURE 12. ELECTRIC BRAKE 4

5

If the brake needs adjustment, have authorized personnel evenly tighten the capscrews until the clearance between the electric magnet and the armature plate is 0.33 to 0.38 mm (0.013 to 0.015 in). See FIGURE 12.

6

ELECTRICAL CABLE SHEAVES

4 3

1.

2.

3.

4.

5.

6.

7.

8.

Lubricate the cable sheaves at the top of the mast and cylinder head using multi–purpose grease.

FILL/BREATHER PLATE ASSEMBLY HOSE CONNECTOR SIGHT GAUGE HYDRAULIC TANK TUBE FILTER ELEMENT GROMMET 8

PALLET CLAMP 7

12293

FIGURE 11. CHANGE THE OIL FILTER

BRAKE If the brake will not hold the lift truck on the grade as described, have the adjustment checked by authorized

Use multi–purpose grease to lubricate the pawls of the pallet clamp.

LIMIT SWITCH ROLLERS AND OTHER LUBRICATION Lubricate limit switch rollers, all pins, linkages, cables and levers as necessary. Use SAE 20 oil or Hyster part number 328388 as shown in the MAINTENANCE SCHEDULE in this section.

15

GENERAL PROCEDURES HOW TO CHARGE THE BATTERY WARNING The acid in the electrolyte can cause injury. If electrolyte is spilled, use water to flush the area. Make the acid neutral with a solution of sodium bicarbonate (soda) and water. Acid in the eyes must be immediately flushed with water.

Batteries generate explosive fumes when they are being charged. Keep fire, sparks and burning material away from the battery charger area. Prevent sparks from the battery connectors.

Charge batteries only in the special area for charging batteries. When charging the batteries, keep the vent caps clean. The battery charger area must have ventilation so that explosive fumes are removed. Disconnect the battery when doing cleaning and maintenance.

If the lift truck has been operated using a low battery or deenergized using the Emergency Stop Knob (see “Emergency Stop Knob” in the OPERATING MANUAL), inspect for welded contacts BEFORE connecting a charged battery. The circuit will not reset and lift truck operation cannot be controlled if the contacts are welded. To check the contacts, see Contacts in this manual.

CAUTION Never connect the battery charger plug to the plug of the lift truck. You can damage the traction control circuit. Always make sure the charger voltage is the correct voltage for the battery.

Correct use of the hydrometer (FIGURE 13.) and proper operation of the battery charger is important.

Operate the battery charger according to the instructions of the charger manufacturer. Never let the battery discharge below the minimum value given by the battery manufacturer. A fully charged battery will have a specific gravity of 1.265 to 1.310 at 25°C (77°F).

Never charge a battery at a rate that will raise the electrolyte temperature above 49°C (120°F). Never permit a battery to stay discharged for long periods.

16

FIGURE 13. HOW TO CHECK SPECIFIC GRAVITY

1. NORMAL CHARGE: This charge is normally given to a battery that is discharged from normal operation. Many customers charge the battery at regular intervals that depend on use. This procedure will keep the battery correctly charged if the battery is not discharged below the limit. Always use a hydrometer to check the battery if the battery is charged at regular intervals. Frequent charging of a battery that has a 2/3 or more charge can decrease the life of the battery.

2. EQUALIZING CHARGE: This charge is at a low rate and balances the charge in all of the cells. The equalizing charge is normally given approximately once a month. It is a charge at a slow rate for three to six hours in addition to the regular charging cycle. Do not give an equalizing charge more than once a week.

The most accurate specific gravity measurement of specific gravity for a charged battery will be after an equalizing charge. If the difference in specific gravity is more than 0.020 between cells of a battery after and equalizing charge, there can be a cell that has a malfunction. Consult your battery dealer.

NOTE: Many customers have battery chargers that can follow a program to automatically charge a battery according to recommendations of the battery manufac-

turer. Use the recommendations of the battery manufacturer for charging the battery.

2 6

7 6

5

4 4

3

3 4 5

7

12057

1 1.

2.

3.

4.

BATTERY COMPARTMENT PANEL LATCH FOR COMPARTMENT PANEL BATTERY STAND ROLLERS

5. BATTERY PULLER 6. RATCHET LOCK LEVER 7. BATTERY

FIGURE 14. HOW TO CHANGE THE BATTERY

HOW TO CHANGE THE BATTERY

Remove the Battery (See FIGURE 15.)

3. Align the battery stand with the battery so that the end of the stand is against the roller frame for the battery. Adjust the capscrew legs of the battery stand so that the tops of the rollers are the same height as the bottom of the battery. Adjust all four capscrew legs of the stand so that the rollers are level. Install the battery puller on the end of the stand at the center. See FIGURE 15. Release the ratchet lock and attach the hook to the lifting hole of the battery. Do not permit the hook to make contact with cell connectors. Make sure the battery cables are not damaged during battery removal. Stand on the base of the battery puller, release the ratchet and operate the crank to pull the battery onto the battery stand.

1. Move the key to the OFF position. Use the Battery Disconnect to disconnect the battery.

4. If the battery is lifted, use a spreader bar and crane to lift the battery from the battery stand.

General

WARNING Batteries are heavy and can cause an injury. Use care to avoid injury. Do NOT put hands, arms, feet and or legs between the battery and a solid object.

To prevent personal injury and battery movement that is not expected, the battery must be level when it is moving. Make sure the battery stand is on a level surface and is aligned and adjusted as described in the following procedure.

2. Move to a position in front of the battery compartment panel on the side for the battery stand. On R30E/ EA/EF units, raise the panel latch and move it to the rear to keep it in the UP position. The panel will tip toward you. See FIGURE 15. On R30ES units, there is a small panel at the bottom of the battery compartment.

Lift and tilt the panel to remove it.

WARNING Make sure the capacity of the crane and spreader bar is greater than the weight of the battery. The weight of the battery is normally shown on the battery case. The maximum battery weight is shown on the lift truck nameplate. The spreader bar must

17

NOT be made of metal or it must have insulated straps.

Batteries are heavy. Use care to avoid injury.

Install the Battery (See FIGURE 15.)

WARNING If the lift truck was operated using a low battery or deenergized using the Emergency Stop Knob (see Emergency Stop Knob in the OPERATING MANUAL), inspect for welded contacts BEFORE connecting a charged battery. The circuit will not reset and lift truck operation cannot be controlled if the contacts are welded. To check the contacts, see Contacts in this manual.

Make sure that the battery voltage and weight of the replacement battery is correct as shown on the nameplate. On R30E/EA/EF units, make sure the battery half of the connector block has the block for the Battery Disconnect Lever.

CAUTION The replacement battery must fit the battery compartment.

1. Make sure the battery is the correct size and weight for the lift truck. The correct battery is specified in the table at the back of this manual. Make sure the battery has clearance for installation and that the battery connector can be connected after installation. Make sure that the battery compartment has the correct spacers for the battery you are installing. The spacers must not let the battery move more than 13 mm (0.5 in) in any direction. The spacers must keep the battery as far from the mast as possible. Have authorized personnel replace or adjust the battery spacers for that battery. See your Hyster Lift Truck Dealer for the correct spacers.

On R30E/EA/EF units, make sure the battery connector has the block for the Battery Disconnect Lever installed. See FIGURE 16. Do not damage the battery cables during installation.

2. Install the battery puller on the lift truck frame at the center of the battery compartment on the side opposite the battery stand. See FIGURE 15. Release the ratchet lock, pass the hook through the battery compartment and attach the hook to the battery lifting hole. Do not permit the hook to make contact with the cell connectors. Stand on the base of the battery puller and operate

18

the crank to pull the battery off the stand into the battery compartment. Make sure the foot switch is released and the key is in the OFF position before connecting the battery.

WARNING Before connecting the battery, make sure the key switch is in the OFF position and the brake is on.

2

1 2

1. BATTERY CABLES 2. BATTERY CONNECTOR

1

12582

FIGURE 16. BATTERY CONNECTOR

HOW TO CHANGE WHEELS AND TIRES How To Change Drive And Steer Tire Raise the front of the lift truck as described in HOW TO PUT A LIFT TRUCK ON BLOCKS in this section. Remove the wheel nuts that fasten the drive/steer wheel to the hub. Slide the wheel out from under the lift truck. Use the reverse procedure to install the wheel.

Tighten the wheel nuts to 136 N.m (100 lbf ft) torque after installation.

CAUTION If the wheels have been removed and installed, check all wheel nuts after 2 to 5 hours of operation. Tighten the nuts in a cross pattern to the correct torque value shown in the Maintenance Schedule table. When the nuts stay tight after an eight hour check, the interval for checking can be extended to 350 hours.

To change the drive tire, the wheel must be pressed out of the rim. The correct tools, equipment and press ring must be used for each size wheel. A press that has a capacity of approximately 36 000 kg (80 000 lb) is also required to press the wheel out of the rim. This is not a job that an operator should attempt. Have the tires

changed by authorized personnel that have the proper tools, equipment and experience.

Similar tires, made from softer or harder material, can be installed as optional equipment.

How To Replace Load Wheels (See FIGURE 17.)

the area between the bearings with the same grease and install the axle sleeve. Install the load wheel, axle and axle nut.

NOTE: On units that have the freezer and corrosion option, add additional grease through each of the grease fittings.

1

CAUTION For correct operation of the wire guidance system, all load wheels must always be replaced at the same time.

Put the base arms up on blocks as described in HOW TO PUT THE LIFT TRUCK ON BLOCKS in this section. To replace the load wheels on R30EA and R30EF units, remove the axle and load wheel. For easier installation on R30E/ES units, remove and install one load wheel before removing the next load wheel. The load wheel brackets are held in the base arms by the load wheels. Remove the axle sleeve from the load wheel.

Completely fill new bearings with the grease shown in the MAINTENANCE SCHEDULE in this section. Install the bearings in the replacement load wheel. Make sure the seal of each bearing is toward the outside. Fill

3

5 7

4 8

6

6

2

2 8

7

4

1. BASE ARM 2. LOAD WHEEL BRACKET 3. LOAD WHEEL 4. AXLE 5. AXLE SLEEVE 6. BEARING 7. AXLE NUT 8. GREASE FITTING (FREEZER CORROSION ONLY)

3 1 12058

FIGURE 17. REPLACE THE LOAD WHEELS

BATTERY SPECIFICATIONS MODEL

R30E/EA/EF

R30E/EA/EF

R30ES

VOLTS

MINIMUM COMPARTMENT SIZE LENGTH X WIDTH

BATTERY SIZE* MIN/MAX LENGTH

WIDTH

MIN

MAX

681 kg 817 kg 1500 lb 1800 lb

24V 368 x 975 mm 14.50 x 38.38 in.

889/972 mm 35.00/38.25 in.

330/362 mm 13.00/14.25 in.

343 x 914 mm 13.50 x 36 in.

N/A 911 mm N/A 35.88 in.

N/A 337 mm N/A 13.25 in.

36V

24V ONL Y

WEIGHT

817 kg 1089 kg 1800 lb 2400 lb

466 kg 550 kg 1025 lb 1210 lb

Compartment width is across width of lift truck. Battery length installed across lift truck, battery width installed front–to–back. * Maximum height for all R30E/EA/EF batteries is 787 mm (31.0 in).

Maximum height for R30ES batteries is 591 mm (23.25 in).

N/A = Minimum battery size is Not Available for the R30ES.

19

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PART NO. 910442

8000 SRM 231

SAFETY PRECAUTIONS MAINTENANCE AND REPAIR • When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and that the load being lifted is balanced. Make sure the crane, cables, and chains have the capacity to support the weight of the load.

• Do not lift heavy parts by hand, use a lifting mechanism.

• Wear safety glasses.

• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift trucks.

• Disconnect the battery ground cable on internal combustion lift trucks.

• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance section.

• Keep the unit clean and the working area clean and orderly.

• Use the correct tools for the job.

• Keep the tools clean and in good condition.

• Always use HYSTER APPROVED parts when making repairs. Replacement parts must meet or exceed the specifications of the original equipment manufacturer.

• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to remove parts.

• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the unit needs repairs.

• Be sure to follow the WARNING and CAUTION notes in the instructions.

• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are flammable. Be sure to follow the necessary safety precautions when handling these fuels and when working on these fuel systems.

• Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the area. Make sure the area is well ventilated.

NOTE: The following symbols and words indicate safety information in this manual:

WARNING Indicates a condition that can cause immediate death or injury!

CAUTION Indicates a condition that can cause property damage!

8000 SRM 231

General

General Threaded fasteners, like bolts, nuts, capscrews, and studs, are made to specifications that describe the mechanical strength and hardness of the fastener.

A fastener used in a design application is selected according to its specifications. Hyster® Company buys parts from many countries. Parts that are purchased must be to Hyster® Company standards.

There are several standards used by these countries in the manufacture of threaded fasteners. Many of these fasteners are similar, but cannot be used as a direct replacement. To make sure that you have the correct fastener, order fasteners and parts through the Hyster® Parts Depot.

Service persons must use replacement fasteners that have the same specifications. Fasteners made to each specification have identification marks for that specification. This specification is commonly called "Grade" for SAE standards and "property class" for metric standards. This section describes the identification of some common fasteners.

The metric system used by Hyster® Company is described as SI (Le Systeme d’Unites or the International System of Units, also called SI in all languages). The SI system of measurement is described in ISO Standard 1000, 1973. A conversion table of common measurements is shown in Table 7.

shown first in the series [M12 = 12 mm, M20 = 20 mm (1/2 = 1/2 in., 3/4 = 3/4 in.)].

The number of threads per inch is normally not shown for inch nomenclature and only the UNC (Unified National Coarse) or UNF (Unified National Fine) is shown. This number of threads per inch is not shown because a UNC or UNF fastener has a standard number of threads per inch for a specific diameter. Metric fasteners show the number of threads per millimeter.

The length of the shank is often indicated as part of the description of a fastener. This length is shown in inches for inch fasteners and in millimeters for metric fasteners.

A capscrew will have the following description: Metric

Inch

M12 × 1.75 × 50

1/2 × 13 UNC × 1-1/2

A

A

B

C

B

C

D

A = Thread Size

A = Shank Diameter

B = Pitch

B = Number of Threads Per Unit of Length

C = Length

C = Type of Thread D = Shank Length

NOMENCLATURE, THREADS The thread design is specified by a series of numbers and letters for inch and metric fasteners. See Figure 1. The diameter of the shank of the fastener is

Figure 1. Thread Design

1

General

8000 SRM 231

STRENGTH IDENTIFICATION The most common property classes for metric fasteners are 8.8 and 10.9. The property class is marked

with a number on the head of the capscrew or on a nut. Property classes less than 8.8 are often not marked.

Table 1. Bolts and Screws

CAUTION When fasteners must be replaced, the new fasteners must be of the same strength or greater than the original fasteners. The new fasteners must also be the correct size.

NOTE: Identification marks are according to bolt strength. The higher the number or the increase in the number of marks indicates increased bolt strength.

2

8000 SRM 231

General

Grades for inch bolts go from 2 to 8. Grade 2 fasteners normally do not have any marks. The following

tables show the marks that identify the grades and property classes for different fasteners.

Table 2. Studs and Nuts

3

General

8000 SRM 231 Table 3. Torque Nuts

4

8000 SRM 231

General Table 4. Torque Nuts with Nylon Insert

5

General

8000 SRM 231

FASTENER TORQUE TABLES Table 5. Torque Values for Metric Fasteners*

Size and Pitch

Property Class 5.8 1

Grade 10.9 3

N•m

lbf ft

N•m

lbf ft

N•m

lbf ft

M3 × 0.5 M3.5 × 0.6 M4 × 0.7 M5 × 0.8 M6 × 1

0.62 0.97 1.44 2.91 4.94

0.5 0.7 1.1 2.1 3.6

0.99 1.55 2.30 4.65 7.90

0.7 1.1 2.1 3.6 6

1.34 2.11 3.13 6.33 10.8

1.0 1.6 2.3 4.7 8

M8 × 1.25 M8 × 1 M10× 1.5 M10 × 1.25

12.0 12.8 23.8 25.1

9 9 18 19

19.2 20.5 38.0 40.1

14 15 28 30

26.1 27.9 52 55

19 21 38 41

M12 × 1.75 M12 × 1.25 M14 × 2 M14 × 1.5

41.4 45.3 66 72

31 33 49 53

66 72 105 115

49 53 77 85

90 98 145 155

66 72 105 115

M16 × 2 M16 × 1.5 M20 × 2.5 M20 × 1.5

105 110 200 225

77 81 150 165

165 175 320 355

122 130 235 260

225 240 435 485

165 175 320 360

M24 × 3 M24 × 2 M27× 3 M27 × 2

345 375 505 550

255 275 370 405

555 605 810 875

410 445 600 645

755 820 1,100 1,190

560 605 810 880

M30 × 3.5 M30 × 3 M30 × 2 M33 × 3.5 M33 × 2

690 715 765 940 1,030

510 530 565 695 760

1,100 1,140 1,220 1,500 1,640

810 840 900 1,100 1,210

1,500 1,550 1,660 2,040 2,240

1,100 1,140 1,230 1,510 1,660

M36 × 4 M36 × 3 M39× 4 M39 × 3

1,200 1,280 1,560 1,640

885 945 1,150 1,210

1,930 2,040 2,490 2,630

1,430 1,510 1,840 1,940

2,620 2,780 3,390 3,570

1,940 2,050 2,500 2,640

M42 × 4.5 M42 × 3 M45 × 4.5 M45 × 3 M48 × 5 M48× 3

1,930 2,070 2,410 2,580 2,900 3,160

1,430 1,530 1,780 1,910 2,140 2,330

3,080 3,320 3,850 4,120 4,630 5,040

2,280 2,450 2,840 3,040 3,420 3,720

4,200 4,510 5,240 5,610 6,300 6,860

3,100 3,330 3,870 4,140 4,650 5,060

* Unless otherwise specified 1 Approximately equal to Grade 2 2 Approximately equal to Grade 5 3 Approximately equal to Grade 8

6

Grade 8.8 2

8000 SRM 231

General Table 6. Torque Values for Inch Fasteners* Grade 2 1

Size and Pitch

Grade 5 2

Grade 8 3

lbf ft

N•m

lbf ft

N•m

lbf ft

N•m

1/4 1/4

20 UNC 28 UNF

4 5

6 6

6 7

9 10

9 10

12 14

5/16 5/16

18 UNC 24 UNF

8 9

11 13

13 14

18 20

18 20

25 28

3/8 3/8

16 UNC 24 UNF

15 17

20 23

23 26

31 36

33 37

44 50

7/16 7/16

14 UNC 20 UNF

24 27

33 36

37 41

50 56

52 58

71 79

1/2 1/2

13 UNC 20 UNF

37 41

50 56

57 64

77 86

80 90

110 120

9/16 9/16

12 UNC 18 UNF

53 59

72 80

82 91

110 125

115 130

155 175

5/8 5/8

11 UNC 18 UNF

73 83

99 110

115 130

155 175

160 180

215 245

3/4 3/4

10 UNC 16 UNF

130 145

175 195

200 225

270 300

280 315

380 425

7/8 7/8

9 UNC 14 UNF

125 140

170 185

320 355

435 480

455 500

615 680

1 1

8 UNC 14 UNF

185 210

255 285

485 540

655 735

680 765

925 1,040

1-1/8 1-1/8

7 UNC 12 UNF

265 300

360 405

595 670

805 905

965 1,080

1,310 1,470

1-1/4 1-1/4

7 UNC 12 UNF

375 415

510 565

840 930

1,140 1,260

1,360 1,500

1,850 2,050

1-3/8 1-3/8

6 UNC 12 UNF

490 560

665 760

1,100 1,250

1,490 1,700

1,780 2,040

2,420 2,760

1-1/2 1-1/2

6 UNC 12 UNF

650 735

885 995

1,460 1,650

1,980 2,230

2,370 2,670

3,210 3,620

* Unless otherwise specified 1 Approximately equal to metric Property Class 5.8 2 Approximately equal to metric Property Class 8.8 3 Approximately equal to metric Property Class 10.9

7

General

8000 SRM 231

CONVERSION TABLE Table 7. Conversion Table for Metric and English Units By

Multiply

To Get

Multiply

By

To Get

× 0.155

= inches

Area inches feet

2

2

2

(in. )

(ft 2)

× 6.452

= centimeters

× 0.093

= meters

2

2

2

(cm )

centimeters

(m 2)

meters

2

2

(cm 2)

(m 2)

× 10.764 = feet

2

2

(in. 2)

(ft 2)

Linear inches (in.)

× 25.4

= millimeters (mm)

millimeter (mm)

× 0.039

= inches (in.)

feet (ft)

× 0.305

= meters (m)

meter (m)

× 3.281

= feet (ft)

yards (yd)

× 0.914

= meters (m)

meter (m)

× 1.094

= yards (yd)

miles (mi)

× 1.609

= kilometers (km)

kilometer (km)

× 0.621

= miles (mi)

Mass ounces (oz)

× 28.35

= grams (g)

grams (g)

× 0.035

= ounces (oz)

pounds (lb)

× 0.454

= kilograms (kg)

kilograms (kg)

× 2.205

= pounds (lb)

tons (2,000 lb)

× 907.18

= kilograms (kg)

kilograms (kg)

× 0.001

= tons (2,000 lb)

tons (2,000 lb)

× 0.907

= metric ton (t)

metric ton (t)

× 1.102

= tons (2,000 lb)

× 1.34

= horsepower (hp)

× 0.145

= pounds/in.

2

(psi)

× 145.04 = pounds/in.

2

(psi)

Power horsepower (hp)

× 0.746

= kilowatts (kW)

kilowatts (kW)

Pressure pounds/in.

2

pounds/in.

2

(psi) (psi)

× 6.895 × 0.007

= kilopascal (kPa)

kilopascals (kPa)

= megapascal (MPa)

megapascals (MPa)

Temperature ( Fahrenheit−32)

× 0.56

= Celsius (C)

( Celsius × 1.8) +32

= Fahrenheit

Torque pound inches (lbf in.)

× 0.113

= Newton meter (N•m)

Newton meter (N•m)

× 8.851

= pound inches (lb f in.)

pound feet (lbf ft)

× 1.356

= Newton meter (N•m)

Newton meter (N•m)

× 0.738

= pound feet (lb f ft)

× 0.621

= miles/hour (mph)

× 0.061

= inches

3

(in. 3)

3

(in. 3)

Velocity miles/hour (mph)

× 1.609

= kilometer/hour (km/h) kilometer/hr (km/h)

Volume inches

3

(in. )

× 16.387

= centimeters

inches

3

(in. 3)

× 0.016

= liters (l)

liters (l)

× 61.024 = inches

quarts, U.S. (qt)

× 0.946

= liters (l)

liters (l)

× 1.057

= quarts, U.S. (qt)

quarts, U.S. (qt)

× 0.83

= quarts, Imp. (qt)

quarts, Imp. (qt)

× 1.205

= quarts, U.S. (qt)

gallons, U.S. (gal)

× 3.785

= liters (l)

liters (l)

× 0.264

= gallons, U.S. (gal)

gallons, U.S. (gal)

× 0.83

= gallons, Imp. (gal)

gallons, Imp. (gal)

× 1.205

= gallons, U.S. (gal)

ounces (oz)

× 29.57

= milliliters (ml)

milliliters (ml)

× 0.034

= ounces (oz)

8

3

3

3

(cm )

centimeters

3

(cm 3)

TECHNICAL PUBLICATIONS 8000 SRM 231

9/00 (3/98)(6/83) Printed in U.S.A.

ALL PARTS ARE SHOWN IN THE NORMAL POSITION FOR THE FOLLOWING CONDITIONS: 1. UNIT STOPPED 2. OPERATOR PLATFORM IS FULLY LOWERED. 3. STEERING IS SET FOR STRAIGHT TRAVEL. 4. OPERATOR IS OFF THE UNIT. *WIRES 19, 20 AND 21 CONNECT DIRECTLY BETWEEN ECM AND THE RECEPTIVE POTENTIOMETER WITH RETURN TO CENTER STEERING.

1

SEE NOTE A.

A. WHEN OPTIONAL LIFT INTERRUPT BATTERY INDICATOR IS INSTALLED, WIRE 13 IS NOT CONNECTED TO PM CONTACTOR. WIRE 53 FROM LIFT INTERRUPT (TERMINAL 6) IS CONNECTED TO PM CONTACTOR. LS1: TRACTION CUT–OUT ABOVE 150 INCHES. LS2: PREVENTS FAST LOWERING BELOW 24 INCHES. LIMITS TRACTION SPEED ABOVE 24 INCHES.

FIGURE 1. SCHEMATIC DIAGRAM, EV–100 MOTOR CONTROLLER (WITHOUT WIRE GUIDANCE)

2

WHEN OPTIONAL LIFT INTERRUPT BATTERY INDICATOR IS INSTALLED, WIRE 13 IS NOT CONNECTED TO PM CONTACTOR. WIRE 53 FROM LIFT INTERRUPT (TERMINAL 6) IS CONNECTED TO PM CONTACTOR.

3

UNUSED WIRES ARE FOLDED BACK AND TAPED

FIGURE 2. WIRING DIAGRAM, EV–100 MOTOR CONTROLLER (WITHOUT WIRE GUIDANCE) (1 of 2)

4

INSTRUMENT PANEL

TO CARRIAGE HARNESS

TO MAST HARNESS

LIFT INTERRUPT BATT. INDICATOR STEERING POTENTIOMETER

FUSE 3 15A

FAN SW.

IGN FUSE 15A SPOTLIGHT SWITCH

ST

BAT ACC

GRD HOUR METER

POWER DISCONNECT

KEY SWITCH

TO MAST HARNESS FAN AND LIGHT HARNESS

TO BATTERY DISCONNECT COMPACTOR STEERING INDICATOR CONTROL MODULE

TO “B–” ON TRACTION SCR PANEL TO PUMP MOTOR (PM) CONTACOTR

LIFT INTERRUPT BATTERY INDICATOR CONTROL STEERING INDICATOR LIGHTS TO ACC TERMINAL ON KEY SWITCH

FIGURE 3. WIRING DIAGRAM, EV–100 MOTOR CONTROLLER (WITHOUT WIRE GUIDANCE) (2 of 2)

5

INSTRUMENT PANEL

TO CARRIAGE HARNESS

TO MAST HARNESS

LIFT INTERRUPT BATT. INDICATOR STEER POTENTIOMETER

FUSE 3 15A

FAN SW.

IGN ST GRD

FUSE 15A SPOTLIGHT SWITCH

HOUR METER

POWER DISCONNECT

BAT ACC

KEY SWITCH

TO MAST HARNESS FAN AND LIGHT HARNESS

TO BATTERY DISCONNECT COMPACTOR STEERING INDICATOR CONTROL MODULE

TO “B–” ON TRACTION SCR PANEL TO PUMP MOTOR (PM) CONTACOTR

LIFT INTERRUPT BATTERY INDICATOR CONTROL STEERING INDICATOR LIGHTS TO ACC TERMINAL ON KEY SWITCH

FIGURE 4. WIRING DIAGRAM, EV–100 MOTOR CONTROLLER (WITH WIRE GUIDANCE) (1 of 2)

6

7

UNUSED WIRES ARE FOLDED BACK AND TAPED

WHEN OPTIONAL LIFT INTERRUPT BATTERY INDICATOR IS INSTALLED, WIRE 13 IS NOT CONNECTED TO PM CONTACTOR. WIRE 53 FROM LIFT INTERRUPT (TERMINAL 6) IS CONNECTED TO PM CONTACTOR.

FIGURE 5. WIRING DIAGRAM, EV–100 MOTOR CONTROLLER (WITH WIRE GUIDANCE) (2 of 2)

8

ALL PARTS ARE SHOWN IN THE NORMAL POSITION FOR THE FOLLOWING CONDITIONS: 1. UNIT STOPPED 2. OPERATOR PLATFORM IS FULLY LOWERED. 3. STEERING IS SET FOR STRAIGHT TRAVEL. 4. OPERATOR IS OFF THE UNIT.

9

WHEN OPTIONAL LIFT INTERRUPT BATTERY INDICATOR IS INSTALLED, WIRE 13A IS NOT CONNECTED TO PM CONTACTOR. WIRE 53 FROM LIFT INTERRUPT (TERMINAL 6) IS CONNECTED TO PM CONTACTOR. UNUSED WIRES ARE FOLDED BACK AND TAPED. LS1: TRACTION CUT–OUT ABOVE 150 INCHES. LS2: PREVENTS FAST LOWERING BELOW 24 INCHES. LIMITS TRACTION SPEED ABOVE 24 INCHES.

FIGURE 6. SCHEMATIC DIAGRAM, EV–100 MOTOR CONTROLLER (WITH WIRE GUIDANCE)

10

LS1: TRACTION CUT–OUT ABOVE 150 IN. F.E. ON MAST (R30E). TRACTION CUT–OUT ABOVE 150 INCHES F.E. ON MAST WITH STEERING ANGLES OF MORE THAN 7 DEGREES (R30EA/EF).

LS2: SPEED REDUCTION ABOVE 24 INCHES OPERATOR PLATFORM ON CARRIAGE. LS3: TRACTION OVERRIDE ON CARRIAGE (OPTIONAL).

LS4: TRACTION CUT–OUT ABOVE 272 INCHES F.E. ON MAST (R30EA/EF).

11

WHEN OPTIONAL LIFT INTERRUPT BATTERY INDICATOR IS INSTALLED, WIRE 13A IS NOT CONNECTED TO PM CONTACTOR. WIRE 53 FROM LIFT INTERRUPT (TERMINAL 6) IS CONNECTED TO PM CONTACTOR. ALL SWITCHES ARE SHOWN IN THE STATIC TRUCK POSITION. FAST LOWER CAN ONLY BE ACHEIVED WHEN PLATFORM IS ABOVE 24 INCHES.

STEERING INDICATOR CONTROL MODULE, STEER INDICATOR LIGHTS, CONTROL MODULE AND WIRE 10 NOT USED WITH SELF–CENTERING STEERING. WHEN SELF–CENTERING STEERING IS USED, STEERING POT CONNECTS DIRECTLY TO ELECTRONIC CONTROL MODULE.

FIGURE 7. SCHEMATIC DIAGRAM, EV–100LX MOTOR CONTROLLER (WITHOUT WIRE GUIDANCE)

12

13

FIGURE 8. WIRING DIAGRAM, EV–100LX MOTOR CONTROLLER–W/OUT WIRE GUIDANCE (1 of 2)

14

56

13

10

A

WHEN OPTIONAL LIFT INTERRUPT BATTERY INDICATOR IS USED, REMOVE WORE 13A FROM THE HOIST CONTACTOR. CONNECT WIRE 53 FROM LIFT INTERRUPT (TERMINAL 6) TO HOIST CONTACTOR, NEG (–) TERMINAL.

B

FOLD BACK AND TAPE UNUSED WIRES.

FUSE 15A 1 3

10

10

BATT

10 74

10

ACC ST

MULTI TURN STEERING POT

IGN GRD

KEY SWITCH

4

1 19

2

3

STEERING INDICATOR CONTROL MODULE

21 20

B3 B2

73

B1

21

19

A5 A4 A3 A2 A1

STEERING IND. LIGHTS 43 45

44 42

10

20

POWER DISCONNECT

42 42 42

TO ACC ON KEY SWITCH

TO MAST HARNESS

13 HOUR METER 56

13C 14

56

A 53

BATTERY INDICATOR 74 55

55

58

10

58

54

13

54

FUSE 15A 35

10

8 7 6 5 4 3 2 1

E

D

F

H

G

J

LIFT INTERRUPT BATTERY INDICATOR – MOUNTED ON CHASSIS

46 41

J

B BDI

1

10

74 56

13 73

F

G

H D E

35 FAN AND LIGHT HARNESS 13

1

TO MAST HARNESS

FIGURE 9. WIRING DIAGRAM, EV–100LX MOTOR CONTROLLER–W/OUT WIRE GUIDANCE (2 of 2) 15

TO CARRIAGE HARNESS 56

13

10 FUSE 15A

A

WHEN OPTIONAL LIFT INTERRUPT BATTERY INDICATOR IS USED, REMOVE WORE 13A FROM THE HOIST CONTACTOR. CONNECT WIRE 53 FROM LIFT INTERRUPT (TERMINAL 6) TO HOIST CONTACTOR, NEG (–) TERMINAL.

B

FOLD BACK AND TAPE UNUSED WIRES.

1 3

10

10 BATT

10

10 74

ACC ST GRD

IGN

KEY SWITCH

4

POWER DISCONNECT 73 TO BATTERY NEGATIVE SCR PANEL

73

TO HOIST CONTACTOR

4

13

HOUR METER

56 56

3

TO BATTERY DISCONNECT 14 CONTACTOR

13C

A 53

BATTERY INDICATOR

74

55

55

58

10

58

54

13

54

FUSE 15A 35

10 E H

D G

F

G D

H

J

36 41

J

B BDI

1

56 73

F

E

35 13

FAN AND LIGHT HARNESS

LIFT INTERRUPT BATTERY INDICATOR MOUNTED ON CHASSIS

1

74 13 10

TO MAST HARNESS

FIGURE 10. WIRING DIAGRAM, EV–100LX MOTOR CONTROLLER – W/ WIRE GUIDANCE (1 of 2) 16

17

FOLD BACK AND TAPE USED WIRES.

FIGURE 11. WIRING DIAGRAM, EV–100LX MOTOR CONTROLLER – W/ WIRE GUIDANCE (2 of 2) 18

LS1: TRACTION CUT–OUT ABOVE 150 IN. F.E. ON MAST (R30E). TRACTION CUT–OUT ABOVE 150 INCHES F.E. ON MAST WITH STEERING ANGLES OF MORE THAN 7 DEGREES (R30EA/EF).

LS2: SPEED REDUCTION ABOVE 24 INCHES OPERATOR PLATFORM ON CARRIAGE. LS3: TRACTION OVERRIDE ON CARRIAGE (OPTIONAL).

LS4: TRACTION CUT–OUT ABOVE 272 INCHES F.E. ON MAST (R30EA/EF).

19

A

WHEN OPTIONAL LIFT INTERRUPT BATTERY INDICATOR IS USED, REMOVE WIRE 13A FROM THE HOIST CONTACTOR AND CONNECT WIRE 53 FROM LIFT INTERRUPT (TERMINAL 6) TO HOIST CONTACTOR. ALL SWITCHES ARE SHOWN IN THE STATIC TRUCK POSITION.

FIGURE 12. SCHEMATIC DIAGRAM, EV–100LX MOTOR CONTROLLER (WITH WIRE GUIDANCE)

20

21

FIGURE 13. CABLING AND DETAIL DIAGRAM

22

FIGURE 14. OPTIONS WIRING AND DETAIL DIAGRAM 23

FIGURE 15. WIRE GUIDANCE CABLING AND DETAIL DIAGRAM 24

11

9

10

10

9

9

13

12

3 15 8 1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

7

FILTER RELIEF VALVE SOLENOID VALVE #1 PUMP MOTOR PUMP CHECK VALVE FLOW REGULATOR ACCUMULATOR VELOCITY FUSE MAIN LIFT CYLINDER FREE LIFT CYLINDER SOLENOID VALVE #2 ORFICE PLUG ORFICE PLUG MANUAL VALVE

14

6

2 5 4

1

FIGURE 16. HYDRAULIC SCHEMATIC 25

7,/7 &</,1'(56 ALL MODELS EXCEPT H3.50-5.50XM (H70-120XM)

PART NO. 910102

2100 SRM 103

SAFETY PRECAUTIONS MAINTENANCE AND REPAIR • When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and that the load being lifted is balanced. Make sure the crane, cables, and chains have the capacity to support the weight of the load.

• Do not lift heavy parts by hand, use a lifting mechanism.

• Wear safety glasses.

• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift trucks.

• Disconnect the battery ground cable on internal combustion lift trucks.

• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance section.

• Keep the unit clean and the working area clean and orderly.

• Use the correct tools for the job.

• Keep the tools clean and in good condition.

• Always use HYSTER APPROVED parts when making repairs. Replacement parts must meet or exceed the specifications of the original equipment manufacturer.

• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to remove parts.

• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the unit needs repairs.

• Be sure to follow the WARNING and CAUTION notes in the instructions.

• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are flammable. Be sure to follow the necessary safety precautions when handling these fuels and when working on these fuel systems.

• Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the area. Make sure the area is well ventilated.

NOTE: The following symbols and words indicate safety information in this manual:

WARNING Indicates a condition that can cause immediate death or injury!

CAUTION Indicates a condition that can cause property damage!

2100 SRM 103

Tilt Cylinder Repair

General This section has a description and the repair procedures for several different types of tilt cylinders. The

number and the design of the parts can be different, but the operation of the tilt cylinders is the same.

Description The tilt cylinders ( Figure 2, Figure 3, Figure 4, and Figure 5 ) are used to move the mast forward and backward. To extend the cylinder rod (tilt forward), oil enters the tilt cylinder port behind the piston. The oil pressure pushes the cylinder rod out of the cylinder. Oil in front of the piston returns to the hydraulic

tank. To retract the cylinder rod (tilt backward), the oil enters the port in front of the piston. The oil pressure pushes the cylinder rod into the tilt cylinder.

The oil behind the piston returns to the hydraulic tank.

Tilt Cylinder Repair REMOVE WARNING Before removing the tilt cylinder(s), tilt the mast forward. Use a chain to hold the mast to the frame, and prevent the mast from moving forward.

1. Disconnect the hydraulic lines at the tilt cylinder.

Install caps on the hydraulic lines and ports.

WARNING Do not push the anchor pins out of the rod end with your fingers. Do not permit the tilt cylinders to drop and cause damage.

2. Remove the retainers for the anchor pins. Push the anchor pins out of the rod end with a tool.

3. Use a lifting device to move large tilt cylinders.

Remove the anchor pins from the frame anchors.

Remove the tilt cylinder from the frame.

DISASSEMBLE 1. Put the tilt cylinder in a vise with soft jaws. Remove the rod end from the rod.

2. Remove the retainer from the tilt cylinder. Remove the rod and piston from the cylinder.

3. Disassemble the tilt cylinder as necessary. See Figure 2, Figure 3, Figure 4, and Figure 5.

CLEAN WARNING Cleaning solvents can be flammable and toxic and can cause skin irritation. When using cleaning solvents, always follow the solvent manufacturer’s recommended safety procedures.

Compressed air can move particles so that they cause injury to the user or to other personnel.

Make sure that the path of the compressed air is away from all personnel. Wear protective goggles or a face shield to prevent injury to the eyes.

Clean all parts in solvent and dry with compressed air.

ASSEMBLE Tilt Cylinders With O-Ring or Single-Lip Seals NOTE: Always use new seals and O-rings. Make sure all parts are clean. Lubricate all parts with clean hydraulic oil.

NOTE: During 1980 and 1981, a change was made in the tilt cylinders used in most lift trucks. The O-ring seal between the retainer and the cylinder shell was moved from above the threads to the area below the threads. A back-up ring was added to increase the strength of the O-ring. The assembly of the tilt cylinders is the same, but caution must be used so that the O-ring seal is not damaged by the threads.

1

Tilt Cylinder Repair

2100 SRM 103

1. Install the O-ring inside the piston bore. See Figure 1. Install the piston on the piston rod. Make sure the O-ring is not damaged. Tighten the nut on the piston rod to the specifications given in Torque Specifications.

2. Install the O-ring, seal ring, and guide ring on the piston. The seal ring must be heated before installation. After heating, it must be pushed into its groove using a ring compressor. Let the seal ring cool and return to its normal shape.

3. If used, install the O-ring and the back-up ring in the groove of the outer retainer. Install the rod

1.

2.

3.

4.

5.

PISTON ROD PISTON RING O-RING O-RING PISTON

6.

7.

8.

9.

10.

seal (O-ring toward the piston) and wiper seal in the inner retainer.

4. Install the retainer on the piston rod. Install the piston and rod assembly and the retainer in the cylinder. If used, install the O-ring on the retainer. Tighten the retainer to specifications given in Torque Specifications.

NOTE: After assembly is complete, install the rod end on the piston rod. Tighten the capscrew on the rod end as specified in Mast section for your specific lift truck.

GUIDE RING NUT CYLINDER SHELL O-RING BACK-UP RING

11.

12.

13.

14.

RETAINER SEAL RING WIPER RING SPACER (SOME MODELS)

Figure 1. Tilt Cylinders with O-Ring or Single Lip Seals

2

2100 SRM 103

Tilt Cylinder Repair

Tilt Cylinders for XM and XMS Models NOTE: The following procedure is for these models: S/H/E/J2.00-3.00XM (S/H/E/J40-65XM) J1.60-2.00XMT (J30-40XM) H/S/E1.25-1.75XM, H/S/E2.00XMS (S/H/E25-35XM, S/H/E40XMS).

NOTE: Always use new seals and O-rings. Make sure all parts are clean. Lubricate all parts with clean hydraulic oil.

1. Install the piston seal and O-ring(s) onto the piston. See Figure 2 and Figure 3. Install the piston onto the cylinder rod. Make sure the piston seal is not damaged. Tighten the nut on the piston rod to the value shown in Torque Specifications.

1.

2.

3.

4.

CYLINDER SHELL NUT PISTON O-RING

5.

6.

7.

8.

SEAL RING PISTON ROD O-RING BACK-UP RING

2. Install a new wiper and rod seal. Install the O-ring and back-up ring onto the retainer.

3. Install the retainer assembly onto the rod.

4. Install the piston and rod assembly into the cylinder. Tighten the retainer to the value shown in Torque Specifications.

NOTE: After assembly is complete, install the rod end on the cylinder rod. Tighten the capscrew on the rod end as specified in Mast section for your specific lift truck.

9. SEAL RING 10. RETAINER 11. WIPER RING

Figure 2. Tilt Cylinders for S/H/E/J2.00-3.20XM (S/H/E/J40-65XM)

3

Tilt Cylinder Repair

1.

2.

3.

4.

CYLINDER SHELL RETAINER ROD WIPER RING

2100 SRM 103

5.

6.

7.

8.

ROD SEAL BACK-UP RING O-RING NUT

9. PISTON 10. PISTON SEAL

Figure 3. Tilt Cylinders for H/S/E/J1.25-1.75XM, XMS, XMT (H/S/E/J25-40XM, XMS, XMT)

Tilt Cylinders for H700-800A and Early Model H700-920B NOTE: Always use new seals and O-rings. Make sure all parts are clean. Lubricate all parts with clean hydraulic oil.

1. Install the thrust plate on the rod. Install the back-up ring and O-ring on the rod. Install the piston on the rod. Install the piston rings and seals on the piston. See Figure 4.

2. Install the lock nut on the rod. Tighten the lock nut until the thrust plate is tight against the rod.

Install the pin in the lock nut and rod if necessary, drill a hole in the rod for the pin. Install the snap ring to hold the pin in position.

4

3. Install the piston and rod assembly in the shell.

Install the seals on the retainer. Install the retainer in the shell.

4. Install the lock ring in the shell, but do not tighten it. Install the capscrews in the lock ring.

Turn the lock ring until it is even with the end of the shell. Install the pipe plug in the lock ring and tighten the plug to 34 to 48 N•m (25 to 35 lbf ft). Tighten the capscrews in the lock ring to 14 to 20 N•m (10 to 15 lbf ft).

5. Install the rod end on the rod. Tighten the capscrews on the rod end to 610 N•m (450 lbf ft).

2100 SRM 103

1.

2.

3.

4.

5.

6.

7.

Tilt Cylinder Repair

CYLINDER SHELL SNAP RING LOCK NUT DOWEL PISTON RING O-RING SEAL RING

8.

9.

10.

11.

12.

13.

14.

PISTON RING PISTON THRUST PLATE O-RING BACK-UP RING PISTON ROD O-RING

15.

16.

17.

18.

19.

20.

21.

BACK-UP RING RETAINER SEAL RING WIPER RING RETAINER RING PLUG CAPSCREW

Figure 4. Tilt Cylinders for H700-800A, Early Model H700-920B

INSTALL

3. Connect the hydraulic lines to the tilt cylinder.

1. Use a lifting device to move large tilt cylinders.

Put the cylinder in the lift truck. Install the anchor pin in the frame. Install the retainer pin or cotter pin.

4. Operate the tilt cylinders. Check for correct operation and leakage. Adjust the tilt cylinders as described in Tilt Cylinder Leak Check and Tilt Cylinder Stroke and Mast Tilt Angle Adjustment.

2. Install the anchor pin at the mast mount. Install the retainer pin or cotter pin for the anchor pin.

Tighten the capscrews for the retainer pins.

5

Tilt Cylinder Repair

2100 SRM 103

Tilt Cylinders Using Chevron Packing NOTE: Always use new seals and O-rings. Make sure all parts are clean. Lubricate all parts with clean hydraulic oil.

NOTE: After assembly is complete, install the rod end on the cylinder rod. Tighten the capscrew on the rod end as specified in Mast section for your specific lift truck.

NOTE: The following procedure is for the H360-650C (early model). See Figure 5.

1.

2.

3.

4.

5.

6.

7.

CYLINDER SHELL NUT PISTON HEAD O-RING NYLON RING PACKING NYLON RING

8.

9.

10.

11.

12.

13.

14.

PISTON HALF (FLAT) PISTON ROD O-RING BACK-UP RING RETAINER O-RING BACK-UP RING

15.

16.

17.

18.

19.

BUSHING PACKING RETAINER RING SETSCREW WIPER RING

Figure 5. Tilt Cylinders with Chevron Packing (Early Model H360-650C)

6

2100 SRM 103

Tilt Cylinder Repair

Install STEP 1.

Install the O-ring and the back-up ring on the bushing. Install the packing in the bushing. The end of the packing must extend 3 mm (0.125 in.) beyond the end of the bushing.

1. O-RING 2. BACK-UP RING

3. PACKING 4. BUSHING

1. O-RING 2. BACK-UP RING

3. BUSHING

1. PACKING

2. PISTON HALF

STEP 2.

Install the O-ring and the back-up ring on the retainer. Use your hand to push the bushing into the retainer. Make sure the O-ring is not damaged during installation. Install the retainer and bushing assembly on the cylinder rod.

STEP 3.

Install the flat piston half on the cylinder rod. Put the O-ring on the rod halfway between the threads and the piston half.

7

Tilt Cylinder Repair

2100 SRM 103

STEP 4.

Install the piston half with the packing on the cylinder rod. Make sure the O-ring fits into the piston groove when the piston half is installed. Install the piston rod nut. Tighten to the specifications given in Torque Specifications.

1. O-RING 2. PISTON HALF

3. PISTON HALF WITH PACKING

1. CYLINDER ROD 2. PISTON AND PACKING

3. ROD NUT

STEP 5.

Push the piston into the cylinder bore. Push the retainer into the bore. Make sure the O-ring is not damaged.

8

2100 SRM 103

Tilt Cylinder Leak Check

STEP 6.

Install a new wiper seal in the retainer. Turn the retainer into the cylinder shell until the threads have started. Push the piston in and out several times to make sure the alignment is correct.

1. WIPER SEAL

2. RETAINER

1. RETAINER

2. SETSCREW

STEP 7.

Tighten the retainer to the specifications given in Torque Specifications. Tighten the setscrew.

Tilt Cylinder Leak Check WARNING Never allow anyone under a raised carriage.

Do not put any part of your body in or through the lift mechanism unless all parts of the mast are completely lowered and the engine is STOPPED. Do not try to find hydraulic leaks by putting your hand on hydraulic components under pressure. Hydraulic oil can be injected into the body by the pressure.

1. Put a capacity load on the forks. Use a safety chain to hold the load to the carriage. Raise the load approximately 2.5 m (8 ft). Put the mast in a vertical position.

2. Measure the distance that the rod for tilt cylinder extends from the shell. Check the distance the rod moves in five or ten minutes. Multiply

the rate in Table 1 by the time of the test and compare the numbers.

3. If the tilt rate is greater than the specifications, lower the mast and remove the load from the forks. Install a valve between the port at the front of the tilt cylinder and the hydraulic line.

Put the load on the forks again. Close the valve.

Tilt the mast forward just past the vertical position. If the mast continues to tilt slowly forward, the seals on the piston are leaking.

4. If the mast does not move, open the gate valve and check the movement again. If the mast moves forward when the gate valve is open, check for leaks in the hydraulic lines and fittings. If no leaks are found, the main control valve can be worn or damaged. Remove the load from the forks when the checks are complete.

9

Torque Specifications

2100 SRM 103 Table 1. Movement Rates (Maximum) for Tilt Cylinders

LIFT TRUCK MODEL

HYDRAULIC OIL TEMPERATURE/MAST TILT RATE 20 C (68 F)

60 C (140 F)

mm/min

in./min

mm/min

in./min

A1.00-1.50XL (A20-30XL)

1.3

0.05

9.1

0.50

E1.25-5.50XL,XM (E25-120XL)

0.8

0.03

5.0

0.20

J1.60-2.00XMT (J30-40XM)

0.8

0.03

5.0

0.20

E/J2.00-3.20XM (E/J40-65XM)

0.8

0.03

5.0

0.20

H1.25-1.75XL (H25-35XL)

0.8

0.03

5.0

0.20

S/H/E1.50-1.75XM, S/H/E2.00XMS (S/H/E25-35XM, S/H/E40XMS)

0.8

0.03

5.0

0.20

H2.00-3.00XL (H40-60XL)

1.1

0.04

7.3

0.30

S/H2.00-3.20XM (S/H40-65XM)

1.0

0.04

6.8

0.30

H3.50-7.00XL (H70-155XL)

1.3

0.05

8.9

0.34

H8.00-16.00XL (H165-360XL)

1.8

0.07

11.7

0.05

H8.00-16.00XM (H170-360HD)

1.8

0.07

11.7

0.05

H20.00-32.00F (H440-700F/FS)

1.3

0.05

3.8

0.15

H36.00-48.00C (H800-1050C)

1.3

0.05

3.8

0.15

J2.00-3.00XL (J40-60XL)

0.8

0.03

5.0

0.20

J25-35A,B

1.3

0.05

3.8

0.15

S1.25-5.50XL (S25-120XL)

0.8

0.03

5.0

0.20

S6.00-7.00XL (S135-155XL)

1.2

0.05

8.2

0.32

Tilt Cylinder Stroke and Mast Tilt Angle Adjustment Adjust the tilt cylinders as described in the section for the Mast.

Torque Specifications PISTON ROD NUT E1.25-1.75XL (E25-35XL) 163 to 190 N•m (120 to 140 lbf ft) J1.60-2.00XMT (J30-40XM) 163 to 190 N•m (120 to 140 lbf ft) E2.00-3.00XL (E40-60XL) 320 to 400 N•m (236 to 295 lbf ft)

10

E/J2.00-3.20XM (E/J40-65XM) 150 N•m (110 lbf ft) E20-30B 244 to 271 N•m (180 to 200 lbf ft) E30-60B, E30-60AC 407 to 475 N•m (300 to 350 lbf ft) E3.50-5.50XL (E70-120XL) 400 to 440 N•m (295 to 325 lbf ft)

2100 SRM 103

Torque Specifications

E60-100B 407 to 440 N•m (300 to 325 lbf ft)

H60-110E 400 to 440 N•m (295 to 325 lbf ft)

H1.25-1.75XL (H25-35XL) 163 to 190 N•m (120 to 140 lbf ft)

H110-150F 678 to 746 N•m (500 to 550 lbf ft)

H/E1.50-1.75XM, H/E2.00XMS (H/E25-35XM, H/E40XMS) 163 to 190 N•m (120 to 140 lbf ft)

H300A 678 to 746 N•m (500 to 550 lbf ft)

H20-30E 136 to 170 N•m (100 to 125 lbf ft) H2.00-3.00XL (H40-60XL) 163 to 190 N•m (120 to 140 lbf ft) S/H2.00-3.20XM (S/H40-65XM) 150 N•m (110 lbf ft) H30-60H, H40-60J 244 to 271 N•m (180 to 200 lbf ft) H3.50-5.00XL (H70-110XL) 400 to 440 N•m (295 to 325 lbf ft) H6.00-7.00XL (H135-155XL) 407 to 440 N•m (300 to 325 lbf ft) H7.00-12.50H (H150-275H) 447 to 475 N•m (330 to 350 lbf ft) H8.00-12.00XL (H165-280XL) 950 to 985 N•m (700 to 725 lbf ft) H13.00-16.00XL (H300-360XL) 1105 to 1140 N•m (815 to 840 lbf ft) H16.00-30.00C (H360-650C) - Early 1356 to 1492 N•m (1000 to 1100 lbf ft) H16.00-30.00C (H360-650C) - Late 1500 to 1600 N•m (1107 to 1181 lbf ft) H17.00-32.00C (H370-700C) 1500 to 1600 N•m (1107 to 1181 lbf ft) H20.00-32.00F (H440-700F/FS) 1500 to 1600 N•m (1107 to 1181 lbf ft) H32.00-44.00B (H700-920B) - Late 1500 to 1600 N•m (1107 to 1181 lbf ft) H36.00-48.00C (H800-1050C) 1500 to 1600 N•m (1107 to 1181 lbf ft) H60-90C 407 to 447 N•m (300 to 330 lbf ft)

H300-350B 447 to 475 N•m (330 to 350 lbf ft) H360-620B 1356 to 1492 N•m (1000 to 1100 lbf ft) H700-800A, H700-920B - Early See Text J2.00-3.00XL (J40-60XL) 320 to 400 N•m (236 to 295 lbf ft) J25-35A 244 to 271 N•m (180 to 200 lbf ft) J25-35B 320 to 400 N•m (236 to 295 lbf ft) J40-60A, J50-60AS 407 to 475 N•m (300 to 350 lbf ft) P40-50A, P60-80A 407 to 447 N•m (300 to 330 lbf ft) P7.00-8.00B (P150-200B) 447 to 475 N•m (330 to 350 lbf ft) S20-30A 136 to 170 N•m (100 to 125 lbf ft) S30-60E, S40-50F 407 to 475 N•m (300 to 350 lbf ft) S40-50C 224 to 271 N•m (165 to 200 lbf ft) S1.25-1.75XL (S25-35XL) 163 to 190 N•m (120 to 140 lbf ft) S25-35XM, S40XMS 163 to 190 N•m (120 to 140 lbf ft) S2.00-3.00XL (S40-60XL) 320 to 400 N•m (236 to 295 lbf ft) S3.00-5.50E (S60-120E) 407 to 440 N•m (300 to 325 lbf ft) S3.50-5.50XL (S70-120XL) 400 to 440 N•m (295 to 325 lbf ft)

11

Torque Specifications

2100 SRM 103

S5.50-7.00A (S125-150A) 542 to 610 N•m (400 to 450 lbf ft)

H7.00-12.50H (H150-275H) 475 to 542 N•m (350 to 400 lbf ft)

S6.00-7.00XL (S135-155XL) 407 to 440 N•m (300 to 325 lbf ft)

H8.00-12.00XL (H165-280XL) 542 to 610 N•m (400 to 450 lbf ft)

RETAINER

H13.00-16.00XL (H300-360XL) 610 to 675 N•m (450 to 500 lbf ft)

E1.25-1.75XL (E25-35XL) 169 to 237 N•m (125 to 175 lbf ft) J1.60-2.00XMT (J30-40XM) 163 to 176 N•m (120 to 130 lbf ft) E2.00-3.00XL (E40-60XL) 400 to 500 N•m (295 to 369 lbf ft) E/J2.00-3.20XM (E/J40-65XM) 170 to 237 N•m (125 to 175 lbf ft) E20-30B 407 to 475 N•m (300 to 350 lbf ft) E30-60B, E30-60AC 475 to 542 N•m (350 to 400 lbf ft) E3.50-5.50XL (E70-120XL) 400 to 500 N•m (295 to 370 lbf ft) E60-100B 576 to 644 N•m (425 to 475 lbf ft) H1.25-1.75XL (H25-35XL) 169 to 237 N•m (125 to 175 lbf ft) H/E1.50-1.75XM, H/E2.00XMS (H/E25-35XM, H/E40XMS) 163 to 176 N•m (120 to 130 lbf ft) H20-30E 203 to 271 N•m (150 to 200 lbf ft) H2.00-3.00XL (H40-60XL) 169 to 237 N•m (125 to 175 lbf ft) S/H2.00-3.20XM (S/H40-65XM) 170 to 237 N•m (125 to 175 lbf ft) H30-60H, H40-60J 407 to 475 N•m (300 to 350 lbf ft) H3.50-5.00XL (H70-110XL) 400 to 500 N•m (295 to 369 lbf ft) H6.00-7.00XL (H135-155XL) 542 to 610 N•m (400 to 450 lbf ft)

12

H16.00-30.00C (H360-650C) - Early 542 to 610 N•m (400 to 450 lbf ft) H16.00-30.00C (H360-650C) - Late 450 to 550 N•m (332 to 406 lbf ft) H17.00-32.00C (H370-700C) 450 to 550 N•m (332 to 406 lbf ft) H20.00-32.00F (H440-700F/FS) 450 to 550 N•m (332 to 406 lbf ft) H32.00-44.00B (H700-920B) - Late 450 to 550 N•m (332 to 406 lbf ft) H36.00-48.00C (H800-1050C) 450 to 550 N•m (332 to 406 lbf ft) H60-90C 475 to 542 N•m (350 to 400 lbf ft) H60-110E 542 to 610 N•m (400 to 450 lbf ft) H110-150F 271 to 305 N•m (200 to 225 lbf ft) H300A H300-350B 475 to 542 N•m (350 to 400 lbf ft) H360-620B 542 to 610 N•m (400 to 450 lbf ft) H700-800A, H700-920B - Early See text J2.00-3.00XL (J40-60XL) 400 to 500 N•m (295 to 369 lbf ft) J25-35A 407 to 475 N•m (300 to 350 lbf ft) J25-35B 400 to 500 N•m (295 to 369 lbf ft) J40-60A, J50-60AS 475 to 542 N•m (350 to 400 lbf ft)

2100 SRM 103

Troubleshooting

P40-50A, P60-80A 475 to 542 N•m (350 to 400 lbf ft)

S25-35XM, S40XMS 163 to 176 N•m (120 to 130 lbf ft)

P7.00-8.00B (P150-200B) 475 to 542 N•m (350 to 400 lbf ft)

S2.00-3.00XL (S40-60XL) 400 to 500 N•m (295 to 370 lbf ft)

S20-30A 203 to 271 N•m (150 to 200 lbf ft)

S3.00-5.50E (S60-120E) 576 to 644 N•m (425 to 475 lbf ft)

S30-60E, S40-50F 475 to 542 N•m (350 to 400 lbf ft)

S3.50-5.50XL (S70-120XL) 400 to 500 N•m (295 to 370 lbf ft)

S40-50C 407 to 475 N•m (300 to 350 lbf ft)

S5.50-7.00A (S125-150A) 176 to 244 N•m (130 to 180 lbf ft)

S1.25-1.75XL (S25-35XL) 169 to 237 N•m (125 to 175 lbf ft)

S6.00-7.00XL (S135-155XL) 542 to 610 N•m (400 to 450 lbf ft)

Troubleshooting PROBLEM Tilt cylinder movement is slow or not smooth.

POSSIBLE CAUSE

PROCEDURE OR ACTION

Air is in the hydraulic system.

Remove air from hydraulic system.

The hydraulic pump is worn or damaged.

Repair or replace hydraulic pump.

Restriction in the hydraulic lines.

Repair hydraulic lines.

Seals in tilt cylinder are damaged.

Replace seals and inspect cylinder bore for damage.

Tilt cylinders have internal damage.

Repair or replace cylinder.

Load is greater than capacity.

Reduce load.

Pressure relief valve(s) is not adjusted correctly or is damaged.

Repair or adjust relief valve(s).

Large leaks between spool and bore.

Replace valve section.

Spool is not fully extended or retracted.

Adjust linkage to spool.

Tilt control spool is damaged.

Repair control valve.

13

Troubleshooting

PROBLEM The tilt cylinders permit the mast to move when the Tilt control lever is in the Neutral position.

14

2100 SRM 103

POSSIBLE CAUSE

PROCEDURE OR ACTION

There are leaks in the hydraulic lines.

Tighten fittings or repair leaks.

Seals in tilt cylinder are damaged.

Replace seals and inspect cylinder bore for damage.

Tilt cylinders have internal damage.

Repair or replace cylinder.

Tilt control spool is damaged.

Repair control valve.

TECHNICAL PUBLICATIONS 2100 SRM 103

9/00 (6/96)(11/95)(5/95)(1/95)(11/94)(3/94)(9/93)(4/93)(5/87)(10/85) Printed in U.S.A.

INTRODUCTION GENERAL This section has the repair procedures for the Vista two-stage and three-stage uprights. A section for troubleshooting and a section for checks and adjustments is given at the end of the section. The descrip-

tion and operation of the uprights is given in the sec-tion VISTA UPRIGHTS, 4000 SRM 382. Repair procedures for the N40-50EA carriage and the R30E/EA/ EA-FS operator platform is also in this section. Repair procedures for the N40-45ER reach carriages is in the section REACH CARRIAGES, 4500 SRM 384.

REPAIRS NOTE: Many of the procedures for the N40-50EA and N40-45ER need the door open. To open this door, remove the capscrew at the top of the left-hand post for the overhead guard to permit the post to move with the door. Then, remove the screw that fastens the door and open the door. Make sure to install and tighten the capscrew at the top of the post after closing the door.

WARNING Lower the lift mechanism completely. Never allow anyone under a raised carriage, operator platform or forks. Do not put any part of your body in or through the mechanism unless all parts of the up-right are completely lowered and the key switch is OFF. Before making any repairs, use blocks and chains on the upright weldments and carriage or operator platform so that they can not move.

Make sure the moving parts are attached to a non-moving part.

FORKS WARNING Forks are heavy and can cause an injury. Do not try to remove forks without using a lifting device.

Replacement (N40-50EA) (See Figure 1) NOTE: This replacement procedure is for the hook type forks used on the standard (not reach) N4050EA carriage. Replacement procedures for the pin type forks on the N40-45ER reach carriages

is in the section REACH CARRIAGES, 4500 SRM 384.

These forks are connected to the carriage by hooks and locking pins. The pins fit through the top fork hooks and into slots on the top crossmember of the carriage. The forks can be removed and installed by aligning them with the removal notch. The removal notch is in the bottom crossmember of the carriage.

Replacement (R30E/EA/EA-FS) (See Figure 1) Each of these forks is connected to the operator platform by a pin near the edge of the platform. The pin fits through a tube welded to the top of the fork. The forks can be removed by raising the operator platform for access.

WARNING Before replacing forks, use blocks and chains on the upright weldments and operator platform so that they can not move. Make sure the moving parts are attached to a non-moving part.

Use blocks and chains to prevent movement of the upright or operator platform. Support the fork, remove the snap ring on the end of the pin and remove the pin. Install the forks using the reverse procedure.

Make sure the hook at the end of the fork engages the plate of the platform. Do not install any shims at this time. Make sure the operator platform is fully lowered. Adjust the lift chains of the operator platform so that the tip of the highest fork is within the specification. See the procedure LIFT

CHAIN ADJUSTMENTS at the end if this section.

After the chains are adjusted, use shims on the top

of the fork (lowest fork tip) at the hook so that the fork tips are aligned within 3.2 mm (1/8 in).

FIGURE 1. FORKS AND N40-50EA STANDARD CARRIAGE OR R30E/EA/EA-FS OPERATOR PLATFORM

CARRIAGE OR OPERATOR PLATFORM NOTE: Removal and repair procedures for the N4045ER reach carriages is in the section REACH CARRIAGES, 4500 SRM 384.

Removal A. Remove the forks as described in FORKS Replacement of this section.

NOTE: On N40-50EA units remove the operator upright guard (clear plastic or wire) for access to the back of the carriage.

B. If the hydraulic system cannot be used, do Step C instead of this step. Tie a rope to the free-lift crosshead (3-stage only). Use the hydraulic system to raise the carriage or operator platform for access to the chain anchors above the top of the main lift truck frame.

C. When the hydraulic system cannot be used, connect a crane to the top of the carriage or operator platform. Make sure that the chains or slings do not damage the parts of the carriage or operator platform. Tie a rope to the free-lift crosshead (3-stage only). Carefully lift the carriage or operator platform for access to the chain anchor(s) above the top of the main lift truck frame. Make sure the lift chain(s) pass over the sheave(s) correctly.

WARNING Before making any repairs, use blocks and chains on the upright weldments and carriage or operator platform so that they can not move.

Make sure the moving parts are attached to a non-moving part.

E. Remove the pin(s) in the chain anchor of the carriage or operator platform to disconnect the lift chain(s). Removing the pin(s) will disconnect the lift chain(s) without changing the chain adjustment. Carefully move the lift chain(s) through the sheave(s) and lay the chain(s) over the top of the lift truck.

F. Use a ladder for access to the R40E/EA/EA-FS operator platform. Make a note of all the connections and disconnect the electrical cables. Carefully move each cable through the sheave and lay it over the top of the lift truck.

G. Use a crane and chains or slings to support the carriage or operator platform. Remove the blocks and chains. Use the crane to slowly lower the carriage or operator platform to the floor. Make sure the carriage or operator platform is resting on the floor and not on chains or slings.

WARNING The carriage or operator platform assembly is heavy and can cause an injury if it tips or falls.

Make sure the carriage or operator platform assembly has stability during and after removal.

H. Fasten the carriage or operator platform so that it can not fall. Use chains or slings to fasten a crane to the inner upright weldment. On two-stage up-rights, remove the snap ring and washer at the rod of each lift cylinder. See Figure 2. The inner upright weldment must be able to move without extending the cylinder rods.

Lift chains and cables can roll over the sheaves to fall and possibly cause an injury if the ends are not fastened. Keep control of the ends of the lift chains and cables as they are disconnected.

I. Use the crane to slowly raise the inner upright weldment so that the carriage rollers come out the bottom of the channels. Make sure the chains or slings do not damage the sheaves or other upright parts.

Make sure there is clearance for the chains or slings as the inner upright weldment moves. Carefully move the carriage away from the lift truck. Carefully lower the inner upright weldment.

D. Use blocks and chains to prevent movement of the upright or operator platform. Use the battery disconnect lever to disconnect the battery. Remove the battery as described in the Operating Manual or the section PERIODIC MAINTENANCE, 8000 SRM 410.

J. On N40-50EA three-stage uprights, have a helper hold the Lowering Lever in the LOWER position.

On R40E/EA/EA-FS three-stage uprights, open the Manual Lowering valve. Pull on the rope to retract the free-lift cylinder rod.

FIGURE 2. DISCONNECTING THE LIFT CYLINDERS K. If any of the carriage or operator platform load rollers must be replaced, make a note of the shim arrangement. When the new load rollers are installed, the shim arrangement normally will be similar.

Installation NOTE: Replace any load rollers that need replacing BEFORE starting this installation procedure. Use the same shim arrangement noted during removal.

A. Make sure the two-stage cylinder rods are not fastened to the inner upright weldment. Use a crane

and chains or slings to raise the inner upright weldment as described in the Removal procedure. Raise the inner upright weldment until it is above the load rollers of the carriage or operator platform. Carefully align the carriage or operator platform load rollers and the upright channel. Slowly lower the inner upright weldment until it engages all the load rollers.

On two-stage uprights, install the washers and snap rings that fasten the cylinder rods to the inner upright weldment.

B. Check the load roller clearance. See the Carriage Or Operator Platform Adjustment procedure at the end of this section.

C. Use a crane and chains or slings to raise the carriage or operator platform for access to the chain anchor(s) above the top of the main lift truck frame.

WARNING Before installing lift chains or cables, use blocks and chains on the upright weldments and carriage or operator platform so that they can not move. Make sure the moving parts are attached to a non-moving part.

Lift chains and cables can roll over the sheaves to fall and possibly cause an injury if the ends are not fastened. Keep control of the ends of the lift chains and cables as they are connected.

D. Use blocks and chains to prevent movement of the upright or operator platform. Install the lift

chain(s) using the pin(s) in the chain anchor(s). Make sure new cotter pin(s) are installed. See the Lift Chain Adjustment procedure at the end of this section to check and if necessary, adjust the lift chains. On N4050EA units, remove the blocks and chains and carefully lower the carriage. Do NOT re-move the blocks and chains for the R40E/EA/EA-FS operator platform. Install the N40-50EA opera-tor upright guard (clear plastic or wire).

E. Use a ladder for access to the R40E/EA/EA-FS operator platform. Carefully move each electrical cable through the sheave and install the cable at the operator platform. Connect the wires according to the notes made during removal. Also see the section DIAGRAMS, 8000 SRM 424 for the correct connections. Remove the blocks and chains and carefully lower the operator platform.

TWO-STAGE UPRIGHT REMOVAL

the overhead guard. Remove the (clear plastic or wire) operator upright guard.

WARNING Fully lower all the upright weldments. On N4045ER units, make sure the forks are fully retracted. Weldments, carriages or operator platform and forks can move suddenly and cause an injury as hydraulic lines are disconnected.

C. Install blocks under the main frame near the upright to support the main frame without changing the height. Make sure the upright, base arms and load wheels do not support any weight so the upright capscrews can be removed. Use chains to fasten the upright channels together at the top of the upright.

NOTE: If the upright assembly will be disassembled, remove the N40-50EA carriage or the R30E/ EA/ EA-FS operator platform before the upright assembly is removed. See CARRIAGE OR OPERATOR PLATFORM Removal in this section. See the section REACH CARRIAGES, 4500 SRM 384 for the procedure to remove the N40-45ER reach carriage.

D. Open the door and remove the access cover over the electrical compartment. Remove the hydraulic tube at the cylinder port of the solenoid valve. Put caps on the port, the upright hose and both ends of the tube to prevent dirt from entering the system. Use wire to fasten the hose in a position to prevent damage during removal of the upright.

A. Disconnect and remove the battery. Refer to the correct procedure in the Operating Manual or the sections PERIODIC MAINTENANCE, 8000 SRM 373 or 8000 SRM 410.

B. On N40-50EA units, remove the capscrews, nuts and washers that fasten the posts of the overhead guard to the overhead guard. Use a crane to remove

E. Disconnect the electrical cable for the reach carriage or the R30E/EA/EA-FS operator platform. Push the cable and connectors through the holes in the lift truck frame to prevent damage to the cable during removal of the upright. On N40-45ER units, remove the hydraulic tubes for the auxiliary functions. Disconnect the the upright hoses and tubes at the maincontrol valve. Use wire to fasten the hoses and cable in a position to prevent damage.

FIGURE 3. VISTA TWO-STAGE UPRIGHT ASSEMBLY

F. Use chains to connect a crane to the top of the upright. Make sure the chains will not damage the sheaves or other parts of the upright assembly. Make sure the chains and crane have the capacity to lift approximately 2000 kg (4500 1bs). Use other chains to fasten all the upright weldments together so that they cannot move. Operate the crane until it gives support to the weight of the upright. Move the crane to a position so that the upright assembly will be lifted vertically.

G. Remove the four large capscrews and washers that fasten the bottom of the upright to the lift truck frame. Hold the spacers and remove the four large capscrews and washers that fasten the top of the upright. Remove all the spacers.

WARNING Lift chains and cables can roll over the sheaves to fall and possibly cause an injury if the ends are not fastened. Keep control of the ends of the lift chains and cables as they are disconnected.

H. Use a ladder to disconnect the lift chains at the top of the outer upright weldment. Remove the pins in the chain anchors to remove the chains without changing the adjustment. Carefully lower the lift chains. Disconnect the electrical wires from the limit switches and remove the cables.

I. Remove the cross tube (horizontal) at the battery side of the bottom of the upright.

J. Operate the crane and carefully move the upright assembly away from the lift truck. Do not damage any hydraulic lines or the electrical cable.

K. Put the upright assembly on the floor so that the back (battery side) of the upright is toward the floor.

DISASSEMBLY (SEE FIGURES 2, 3 AND 4) NOTE: This procedure does NOT include the removal of the carriage or operator platform. Remove the carriage or operator platform before starting this procedure. See the CARRIAGE OR OPERATOR PLATFORM Removal in this section to remove the standard carriage or operator platform. See the section REACH CARRIAGES, 4500 SRM 384 to remove the N40-45ER reach carriages.

A. If necessary, remove the overhead guard and the (clear plastic or wire) operator upright guard on N4050EA or N40-45ER units.

WARNING Make sure the battery side of the upright is toward the floor so that the front of the upright is up for easier disassembly. Make sure the upright weld-ments are fastened together so that the weldments will only slide when being moved during disassembly.

B. If necessary, remove the lift chains by removing the pin in the chain anchor. Removing the pin will allow chain removal without changing the adjustment.

C. Remove the snap rings and washers from the top of each lift cylinder. Use a pry bar to move the inner upright weldment approximately 152 - 305 mm (6 12 in) out the top of the outer upright weldment. Remove the chain and hose sheaves.

D. Install a sling near the center of each channel of the inner upright weldment so that it will be balanced.

The slings must pass through the loop at the end of the sling so that the sling tightens and does not slip on the channel as the weldment is lifted. Fasten a crane to the slings.

E. Use the crane to move the inner upright weldment out of the outer upright weldment. Move the upright weldment until the bottom rollers of the inner upright weldment touch the top rollers of the

outer upright weldment. Use the crane to raise the top of the inner upright weldment so that it is at an angle of approximately 30°. Lift the weldment straight up to remove the inner from the outer upright weldment. Put the weldment flat on the floor so that it cannot fall.

F. Clean the area at the hydraulic fittings for the lift cylinders. Disconnect the fittings. Put caps on the open fittings and cylinder port to prevent dirt from entering the system. Remove the snap rings at the bottom of each cylinder.

G. Install a sling near the center of the lift cylinder in the same manner used for the upright weldment removal. Remove the capscrew, washer and spacer that fastens the cylinder to the outer upright channel. See Figure 2. Use the crane to move the cylinder out of the base hole and remove the cylinder from the upright. Repeat the procedure to remove the other cylinder.

H. Remove the snap rings from the lower and upper load rollers. Make a note of the shim arrangement as each load roller is removed. The shim arrangement will be approximately the same when the upright is assembled.

I. Remove the strip bearings from the outer upright weldment. See Figure 4. Make a note of the shim arrangement during removal of the strip bearings for correct installation during assembly.

J. Disassemble the sheaves and rollers as necessary for repair and cleaning.

CLEANING AND INSPECTION NOTE: These cleaning and inspection procedures apply to both the two-stage and three-stage uprights.

FIGURE 4. LOAD ROLLER AND STRIP BEARING ARRANGEMENT

CAUTION Do NOT use steam to clean the lift chains, sheaves or load rollers. The sheaves and roller bearings are sealed and permanently lubricated.

Do not use compressed air on the bearings. The air can force the lubricant out of the bearings.

Follow the manufactures instructions when using solvent.

FIGURE 5. CHAIN PARTS AND WEAR A. Wash the lift chains with solvent. Use compressed air to dry the chains. Inspect the chains for wear and damage.

B. Inspect the lift chains for cracks or broken links and pins. Check for corrosion or worn holes in the links. When the pins or the holes wear, the chain becomes longer. The chain links that run over the chain sheaves have the most wear. If a chain is 3% longer than a new chain, the chain must be replaced. If a chain scale is available, check the lift chains as shown in Figure 5. If a chain scale is not available, measure 20 links of chain. Compare the measurements with the lengths given in the table of Figure 5. Replace the chains if the increase in length is 3% or greater.

WARNING Never replace just the worn section of a chain.

Replace the complete chain. Never replace just one chain of a chain pair. Replace both chains.

worn so that they are not round. Replace chain anchor pins that are worn or have cracks.

WARNING Commercial cleaning solvents can be flammable and toxic, and cause severe skin irritation. When using commercial cleaning solvents, always comply with the solvent manufacturer’s recommended safety precautions.

E. Clean the upright weldments with steam or solvent.

F. Inspect the sliding and rolling surfaces. Inspect the welds around the stub shafts.

WARNING Do NOT weld on uprights. Get information from your Hyster lift truck dealer before welding on uprights.

LIFT CYLINDERS

C. For chains that can be used again, put the chains in SAE 30 oil for 12 hours.

D. Inspect the chain anchors and pins. Replace chain anchors that have broken fingers, or holes

NOTE: The lift cylinders are removed during disassembly of the upright. To repair the cylinders, see the LIFT CYLINDERS section, 4000 SRM 135 for the correct service procedures.

ASSEMBLY NOTE: The shims for the load rollers keep the channels of the upright weldments parallel and give correct clearance. During assembly, the arrangement of the shims will be the same or approximately the same as they were before disassembly. Check the clearance and adjust for wear or changes from the repairs.

The strip bearings at the top of the outer upright weldment and the bottom of the inner upright weldment are also adjusted using shims. See the Checks And Adjustments in this section for the instructions to make the necessary adjustments.

A. Assemble the load rollers, sheaves and strip bearings on the upright weldments and carriage or operator platform as necessary. Make sure to keep the same shim arrangement noted during disassembly. Apply a thin layer of multi-purpose grease to the strip bearings and the bearing and roller surfaces of the channels.

B. Make sure the cylinders are assembled and install a sling near the center of the cylinder as during removal. Use a crane to move the cylinder into position in the outer upright weldment. Install the snap ring on the bottom of the cylinder. Install the capscrew, washer and spacer to fasten the cylinder shell to the channel. Repeat the procedure to install the other cylinder.

C. Use the crane to move the inner upright weldment into position over the outer upright weldment.

Fasten the slings to the centers of the channels to balance the weldment as during removal. Make sure the inner upright weldment is at approximately a 30° angle with the bottom load rollers in the notch near the top load rollers of the outer upright channels. Slowly lower the inner upright weldment and insert it into the outer upright weldment.

D. Check the clearance of the load rollers and the strip bearings. Make the necessary adjustments as described in Checks And Adjustments.

E. With the inner upright weldment approximately 152 - 305 mm (6 - 12 in) out of the outer upright weldment, install the chain and hose sheaves. Move the inner upright weldment into the outer upright

weldment so that the tops of the cylinder rods are through the holes in the inner upright channels. Install the washers and snap rings to fasten the cylinder rods to the channels.

INSTALLATION NOTE: To make alignment of the upright, spacers and lift truck frame during installation, make two to four alignment studs. Cut the heads off extra mount capscrews and grind the end into a dull point.

A. Install the alignment studs in the bottom mount holes. Install the bottom spacers on the studs.

B. Use chains to fasten the upright weldments together so that they cannot move. Connect a crane to the top of the upright assembly. Make sure the crane and chains have the capacity to lift the upright assembly. Make sure the chains will not damage the sheaves or other parts of the upright assembly.

WARNING Upright assemblies are heavy and can cause an injury when moving. NEVER put any part of your body between the upright and a solid object when the upright is being moved.

C. Raise the upright assembly to a vertical position.

Install the cross tube (horizontal) at the battery side of the bottom of the upright. Carefully move the upright assembly into approximately the correct position near the alignment studs. Install the electrical cables and hydraulic lines through the upright and frame holes as the upright moves into the correct position. The upright and spacers are in correct alignment when the studs can be removed without using a tool. Hold the top spacers and install the mount capscrews, washers and the spacers. The longer capscrews are installed at the bottom of the upright. Replace all the alignment studs with capscrews. Tighten all eight capscrews to 380 N.m (280 1bf ft) torque.

D. Install and connect all the hydraulic lines and lowering control valves. On N40-45ER or R30E/ EA/ EA-FS units, connect the electrical cable for the carriage or operator platform.

E. If the carriage or operator platform was not installed with the uprights, install the carriage or op-

erator platform as described in Carriage Or Operator Platform Installation in this section. Make sure to install the electrical cables and hydraulic lines. Apply grease to the channels of the inner upright weldment for the carriage or operator platform load rollers.

F. Check the clearance of the load rollers as described in Checks And Adjustments.

G. If necessary, install the lifting chains. Use new cotter pins at the chain anchor pins. If necessary, adjust the length of the lift chains as described in Checks And Adjustments.

H. On N40-50EA or N40-45ER units, install the overhead guard and the (clear plastic or wire) operator upright guard. Tighten the capscrews for the overhead guard to 380 N.m (280 1bf ft) torque. Install the capscrews, washers and nuts that fasten the legs to the overhead guard.

THREE-STAGE UPRIGHT REMOVAL NOTE: If the upright assembly will be disassembled, remove the N40-50EA carriage or the R30E/ EAfEAFS operator platform before the upright assembly is removed. See CARRIAGE OR OPERATOR PLATFORM Removal in this section. See the section REACH CARRIAGES, 4500 SRM 384 for the procedure to remove the N40-45ER reach carriage.

WARNING Fully lower all the upright weldments. On N4045ER units, make sure the forks are fully retracted. Weldments, carriages or operator platform and forks can move suddenly and cause an injury as hydraulic lines are disconnected.

The removal procedure of the three-stage upright is similar to the removal procedure for the two-stage upright. See TWO-STAGE UPRIGHT Removal in this section for the correct procedure.

DISASSEMBLY (See Figures 3, 4 and 6) NOTE: This procedure does NOT include the removal of the carriage or operator platform. Remove the carriage or operator platform before starting this procedure. See the CARRIAGE OR OPERATOR PLATFORM Removal in this section to re-move the standard carriage or operator platform.

See the section REACH CARRIAGES, 4500 SRM 384 to remove the N40-45ER reach carriages.

A. If necessary, remove the overhead guard and the (clear plastic or wire) operator upright guard on N4050EA or N40-45ER units.

WARNING Make sure the battery side of the upright is toward the floor so that the front of the upright is up for easier disassembly. Make sure the upright weld-ments are fastened together so that the weldments will only slide when being moved during disassembly.

B. If necessary, remove the lift chains by removing the pin in the chain anchor. Removing the pin will allow chain removal without changing the adjustment.

C. Install a sling near the center of the free-lift cylinder. The sling must pass through the loop at the end of the sling so that the sling tightens and does not slip on the cylinder as it is lifted.

D. Remove the capscrews, spacers, washers and nuts that fasten the shell of the free-lift cylinder to the inner upright weldment. Remove the hydraulic fitting at the bottom of the cylinder. Install plugs to keep dirt out of the cylinder and hydraulic lines. Remove the snap ring that fastens the bottom of the cylinder to the upright weldment. Use a crane to remove the cylinder.

FIGURE 6. VISTA THREE-STAGE UPRIGHT ASSEMBLY

E. Use a pry bar to move the inner upright weld-ment approximately 1/2 to 3/4 out of the intermediate upright weldment. Remove the snap rings and washers from the top of each main-lift cylinder. Move the intermediate upright weldment approximately 152 - 305 mm (6 - 12 in) out the top of the outer upright weldment. Remove the chain and re-move the hose sheaves at the top of the intermediate upright weldment.

F. Install a sling near the center of each channel of the inner upright weldment so that it will be balanced.

The slings must pass through the loop at the end of the sling so that the sling tightens and does not slip on the channel as the weldment is lifted. Fasten a crane to the slings.

G. Use the crane to move the inner upright weldment out of the outer upright weldment. Move the upright weldment until the bottom rollers of the inner upright weldment touch the top rollers of the outer upright weldment. Use the crane to raise the top of the inner upright weldment so that it is at an angle of approximately 30°. Lift the weldment straight up to remove the inner from the outer upright weldment.

Put the weldment flat on the floor so that it cannot fall.

H. Use the procedure of steps F and G to remove the intermediate upright weldment from the outer upright weldment.

I. Clean the area at the hydraulic fittings for the mainlift cylinders. Disconnect the fittings. Put caps on the open fittings and cylinder port to prevent dirt from entering the system. Remove the snap rings at the bottom of each cylinder.

J. Install a sling near the center of one main-lift cylinder in the same manner used for the upright weldment removal. Remove the capscrew, washer and spacer that fastens the cylinder to the outer upright channel. See Figure 2. Use the crane to move the cylinder out of the base hole and remove the cylinder from the upright. Repeat the procedure to remove the other main-lift cylinder.

K. Remove the snap rings from all load rollers. Make a note of the shim arrangement as each load roller is removed. Remove the snap rings from all the sheaves.

Make a note of the shim arrangement as each sheave is removed. All shim arrangements will be approximately the same when the upright is assembled.

L. Remove the strip bearings from the outer upright weldment. See Figure 4. Make a note of the shim arrangement during removal of the strip bearings for correct installation during assembly.

M. Disassemble the sheaves and rollers as necessary for repair and cleaning.

CLEANING AND INSPECTION The procedures for cleaning and inspecting the threestage uprights are the same as the procedures for the two-stage uprights. See Cleaning and Inspection for the Two-Stage Uprights for the correct procedures.

LIFT CYLINDERS NOTE: The lift cylinders are removed during disassembly of the upright. To repair the cylinders, see the LIFT CYLINDERS section, 4000 SRM 135 for the correct service procedures.

ASSEMBLY (See Figures 3, 4, 6 and 7) NOTE: The shims for the load rollers keep the channels of the upright weldments parallel and give correct clearance. During assembly, the arrange-ment of the shims will be the same or approximately the same as they were before disassembly. Check the clearance and adjust for wear or changes from the repairs.

The strip bearings at the top of the outer upright weldment and the bottom of the inner upright weldment are also adjusted using shims. See the Checks And Adjustments in this section for the instructions to make the necessary adjustments.

A. Assemble the load rollers, sheaves and strip bearings on the upright weldments and carriage or operator platform as necessary. Assemble the

sheaves on the free-lift cylinder. Make sure to keep the same shim arrangement noted during disassembly. Apply a thin layer of multi-purpose grease to the strip bearings and the bearing and roller surfaces of the channels.

rollers in the notch near the top load rollers of the outer upright channels. Slowly lower the intermediate upright weldment and insert it into the outer upright weldment.

D. Check the clearance of the load rollers and the strip bearings. Make the necessary adjustments as described in Checks And Adjustments.

E. With the intermediate upright weldment ap-proximately 152 - 305 mm (6 - 12 in) out of the outer upright weldment, install the chain and hose sheaves.

Move the intermediate upright weldment into the outer upright weldment so that the tops of the main-lift cylinder rods are through the holes in the intermediate upright channels. Install the washers and snap rings to fasten the cylinder rods to the channels.

F. Use the procedure of step C to install the inner upright weldment. Check the clearance of the load rollers and the strip bearings. Make the necessary adjustments as described in Checks And Adjustments.

G. Install the outer lift chains between the top of the outer upright weldment and the inner upright weldment as follows: 1. Slide the inner upright weldment for access to the chain anchors.

FIGURE 7. INSTALLING THE OUTER LIFT CHAINS B. Make sure the cylinders are assembled and install a sling near the center of one main-lift cylinder as during removal. Use a crane to move the cylinder into position in the outer upright weldment. Install the snap ring on the bottom of the cylinder. Install the capscrew, washer and spacer to fasten the cylinder shell to the channel. Repeat the procedure to install the other main-lift cylinder.

C. Use the crane to move the intermediate upright weldment into position over the outer upright weldment. Fasten the slings to the centers of the channels to balance the weldment as during removal. Make sure the intermediate upright weldment is at approximately a 30° angle with the bottom load

2. Connect a piece of wire approximately 1 meter (3 feet) long to the end of each lift chain. Use the wire to pull each lift chain into position between the channels of the inner and intermediate upright weldments. Connect the ends of the chains to the chain anchors at the bottom of the inner upright weldment. Use new cotter pins during installation of the chains.

3. Use the wires to pull the chains up between the chain sheaves and the top load rollers on the intermediate upright weldment. Look between the inner and intermediate upright weldments to see the positions of the lift chains. If necessary, use a thin screwdriver to move each lift chain to the inside edge of the inner upright weldment. Remove the wires.

4. Install the chain, hose and cable sheaves as removed during disassembly. Lubricate the

bearings with multi-purpose grease during installation.

5. Connect each end of a wire approximately 2 metre (6 feet) long to the end of each lift chain as shown in Figure 7.

bly to the free-lift cylinder. Adjust the cylinder so that the cylinder shell is parallel to the sides of the inner upright weldment + 3.0 mm (+ 0.12 in). Install the hydraulic lines to the free-lift cylinder. See Figure 8.

INSTALLATION NOTE: To make alignment of the upright, spacers and lift truck frame during installation, make two to four alignment studs. Cut the heads off extra mount capscrews and grind the end into a dull point.

A. Install the alignment studs in the bottom mount holes. Install the bottom spacers on the studs.

B. Use chains to fasten the upright weldments together so that they cannot move. Connect a crane to the top of the upright assembly. Make sure the crane and chains have the capacity to lift the upright assembly. Make sure the chains will not damage the sheaves or other parts of the upright assembly.

WARNING Upright assemblies are heavy and can cause an injury when moving. NEVER put any part of your body between the upright and a solid object when the upright is being moved.

FIGURE 8. HYDRAULIC DIAGRAM VISTA THREE-STAGE UPRIGHT 6. Pull on the wires to pull the inner upright weldment into the intermediate upright weldment. Remove the wires from the chains. Connect each chain to the anchors on the outer upright weldment. Use new cotter pins during installation of the chains. If necessary, adjust the length of the lift chains as described in Checks And Adjustments.

H. Install a sling near the center of the free-lift cylinder as during removal. Use a crane to move the cylinder into position in the inner upright weldment.

Install the capscrews, spacers, washers and nuts that fasten the shell of the free-lift cylinder to the inner upright weldment. Install the snap ring that fastens the bottom of the cylinder to the upright weldment.

If necessary install the crosshead assem-

C. Raise the upright assembly to a vertical position.

Install the cross tube (horizontal) at the battery side of the bottom of the upright. Carefully move the upright assembly into approximately the correct position near the alignment studs. Install the electrical cables and hydraulic lines through the upright and frame holes as the upright moves into the correct position. The upright and spacers are in correct alignment when the studs can be removed without using a tool. Hold the top spacers and install the mount capscrews, washers and the spacers. The longer capscrews are installed at the bottom of the upright. Replace all the alignment studs with capscrews. Tighten all eight capscrews to 380 N.m (280 1bf ft) torque.

D. Install and connect all the hydraulic lines and lowering control valves. On N40-45ER or R30E/ EA/ EA-FS units, connect the electrical cable for the carriage or operator platform.

E. If the carriage or operator platform was not installed with the uprights, install the carriage or operator platform as described in Carriage Or Operator Platform Installation in this section. Make sure to install the electrical cables and hydraulic lines. Apply grease to the channels of the inner upright weldment for the carriage or operator platform load rollers.

F. Check the clearance of the load rollers as described in Checks And Adjustments.

G. If necessary, install the lifting chains. Use new cotter pins at the chain anchor pins. If necessary, ad-just the length of the lift chains as described in Checks And Adjustments.

H. On N40-50EA or N40-45ER units, install the overhead guard and the (clear plastic or wire) operator upright guard. Tighten the capscrews for the overhead guard to 380 N.m (280 1bf ft) torque. Install the capscrews, washers and nuts that fasten the legs to the overhead guard.

GENERAL PROCEDURES REPLACING LOAD WHEELS (See Figure 9) NOTE: This procedure applies to both the two-stage and three-stage uprights.

For easier installation, remove and install one load wheel before removing the next load wheel. The load wheel brackets are held in the load arms by the load wheels. Make sure the base arms and load wheels do not support any weight. If necessary, install blocks under the base arms. Remove the axle nut, axle with washer and the load wheel. Remove the axle sleeve from the load wheel. Completely fill new bearings with the grease shown in the MAINTENANCE SCHEDULE of the section PERIODIC MAINTENANCE, 8000 SRM 373 or 410. Install the bearings in the replacement load wheel. Make sure the seal of each bearing is toward the outside of the load wheel. Fill the area between the bearings with the same grease and install the axle sleeve. Install the washer on the axle. Install the load wheel, axle and axle nut.

NOTE: On units that have the freezer and corrosion option, add additional grease through each grease fitting.

FIGURE 9. REPLACING LOAD WHEELS

CHECK AND ADJUSTMENTS CHECKING FOR LEAKING IN THE LIFT SYSTEM WARNING During the test procedures for the hydraulic system, use chains to fasten the load to the forks to

prevent the load from falling. Keep all people away from the lift truck during the tests.

A. Leaks Outside the Hydraulic Lift System: 1. Operate the hydraulic system. Put a capacity load on the forks. Make sure there is enough

overhead clearance. Raise and lower the load several times. Check for leaks.

B. Leaks Inside the Hydraulic Lift System: 1. Put a capacity load on the forks. Make sure there is enough clearance to raise the carriage or operator platform. Raise the carriage or operator platform until all the upright weldments are extended. If the carriage or operator platform slowly lowers with the LOWER controls released, there are leaks inside the hydraulic system. Maximum lowering of the carriage or operator platform from inside leaks in the lift system is 50 mm (2 in) in 10 minutes. This maximum rate for leaks is for hydraulic oil at 32°C (90°F). If the oil temperature is 71°C (160°F), the maximum lowering rate is 150 mm (6 in) in 10 minutes.

2. Check the lift cylinders for internal leaks. Install a gate valve at the cylinder port of the Lift/ Lower solenoid valve. Connect the hydraulic line to the gate valve. Put an 80-90% capacity load on the forks. Fasten the load to the forks. Raise the carriage or operator platform until all the upright weldments are extended. Close the gate valve. If the carriage or operator platform and upright weldments slowly lower, the seals in the lift cylinders have leaks.

3. If the carriage or operator platform does not move, open the gate valve and check the movement again. If the carriage or operator platform lowers when the gate valve is open, check for leaks in the hydraulic lines and fittings. If no leaks are found, the control valve or solenoid valve can have a defect. Remove the load from the forks.

LIFT CHAIN AD JUSTMENTS (See Figure 10) The following specifications must be correct for correctly adjusted lift chains: 1. The chain tension must be the same for each chain of the chain set. Chains that have the same tension will move the same amount using the same pressure.

2. The chain lengths must be equal for each chain set and the length must be correct for the upright height.

3. The chains must travel freely through the complete raising and lowering cycle.

A. Put an 80-90% capacity load on the forks.

Lower the forks as much as possible.

FIGURE 10. LIFT CHAIN ADJUSTMENTS

FIGURE 11. LOAD ROLLER AND SIDE CLEARANCE ADJUSTMENT DIAGRAM

B. Check the amount of the bottom carriage or operator platform roller extending below the inner upright weldment of the upright. No more than one third of the roller can extend below the upright. If the rollers are too low, adjust the chain anchors. Make sure each anchor is adjusted the same amount.

NOTE: When the chain adjustments are complete, make sure that the threads on the nuts of the chain

anchors are completely engaged. Make sure that all of the adjustment is not removed from the chain anchors so that they can not move in their sockets.

CAUTION The minimum thread extending above the nut of the chain anchor is two times the chain pitch. Periodic checks must be made to correct chain adjustments for wear.

C. Remove the load from the forks. Check the clearance of the carriage or operator platform when the upright is fully extended. The carriage or operator platform stops must not touch the stop at the top of the inner upright weldment. The chains are too short if the carriage or operator platform touches the stop.

Lower the carriage or operator platform completely.

Check that the top of the forks are 70-83 mm (2.753.25 inches) above the floor for the N40-50EA, N4045ER and R30E units. Check that the top of the forks are 159-171 mm (6.25-6.75 inches) above the floor for the R30EA and R30EA-FS units. If the forks are not within the specified height above the floor, the chains need adjusting. If the chains are too long or too short, adjust the chain anchors. Make sure each anchor is adjusted the same amount.

2. The maximum clearance between the load roller and the upright weldment at the POINT OF TIGHTEST FIT is 0.8 mm (0.030 in).

3. The number of shims between the roller and upright weldment on a stub shaft must be approximately the same as the stub shaft in the opposite channel. The upright weldments will be approximately in the center.

B. Adjust the upright load rollers as follows: 1. Use a crowbar to move the upright weldments from side to side to measure the amount of movement. Repeat in a minimum of three different positions of the upright weldments.

NOTE: If the chain anchors are adjusted too loose, the Lowering Interrupt Switches will prevent lowering of the platform and upright.

2. Separate the uprights and change the shim arrangements as needed. Assemble the upright weldments. Slide the upright weldment all the way to the top and bottom to find the tightest fit.

D. Three-stage upright chain adjustment: Adjust the main lifting chains until the top of the inner upright weldment is at the same height as the top of the outer upright weldment. Adjust the free-lift chain as described in step C.

3. Repeat steps 1 and 2 until the clearance is not more than 0.8 mm (0.030 in) at the point of tightest fit.

UPRIGHT ADJUSTMENTS

4. Measure the distance on the top and bottom between the upright weldments. Move shims from one side of the roller to the other to keep the distance equal between the top and bottom so that the uprights are parallel.

NOTE: Each load roller is kept in the correct position on the stub shaft using shims. The shims are installed on both sides of the load roller. Do not add or remove shims from the stub shafts. To change the position of the roller on the stub shaft, move the shims from one side of the roller to the other.

C. Adjust the strip bearings. Insert shims between the strip bearing and the upright weldment. Adjust the clearance until there is less than 0.8 mm (0.030 in) at the point of tightest fit. See Figure 12.

During assembly, the shim arrangement will be approximately the same as before disassembly. Make notes of each shim arrangement during disassembly.

Check the clearance and adjust for wear or change from the repairs.

D. Slowly raise and lower the upright several times without a load. The upright components must raise and lower smoothly in the correct sequence. The inner upright weldments and the carriage or operator platform must lower completely.

A. The load rollers control the alignment of the uprights. The alignment conditions are given in the steps following this paragraph with the most important condition first. See Figure 11 for the correct ad-justments.

1. The vertical upright weldments must be parallel to each other to decrease wear.

NOTE: Some parts of the upright move at different speeds during raising and lowering.

CARRIAGE OR OPERATOR PLATFORM ADJUSTMENT (See Figures 10 and 11) NOTE: This procedure does NOT include the adjustment of the reach carriages. See the section

REACH CARRIAGES, 4500 SRM 384 to adjust the N40-45ER reach carriages.

A. Install the load rollers on the carriage or operator platform. Install the shims for the rollers in the same sequence on the stub shaft as they were before disassembly. There must be no shims between the roller and the weldment on the two top rollers only.

B. Use a crane to raise the carriage or operator platform within the inner upright weldment. Find the point of tightest fit between the load rollers and the inner upright weldments.

C. Remove the carriage or operator platform from the upright. Adjust the shim arrangement for each roller for clearance between the roller and the inner upright weldment. The clearance must be 0.1 - 0.8 mm (0.005 - 0.030 in) at the POINT OF TIGHTEST FIT. Repeat steps B and C if necessary.

D. Keep the shim arrangement on each side of the carriage or operator platform approximately equal.

The carriage or operator platform must run parallel with the inner upright weldment.

E. After adjustment, lubricate the upright roller channels with a thin layer of grease.

CAUTION Too much grease can cause the rollers to slide and wear flat areas on the rollers.

F. Slowly raise and lower the upright several times without a load. The upright components must raise and lower smoothly in the correct sequence. The inner upright weldments and the carriage or operator platform must lower completely.

NOTE: Some parts of the upright move at different speeds during raising and lowering.

FIGURE 12. LOAD ROLLER AND STRIP BEARINGS

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INTRODUCTION GENERAL This section has the descriptions and the operations for the Vista uprights. The repair procedures for the Vista uprights are in the section VISTA UPRIGHTS Repair, 4000 SRM 383. The information for the lift cylinders is in the section LIFT CYLINDERS 4000 SRM 135. The information for the N40-50EA standard carriage and the R30E/EA/ EA-FS operator platform is also in this section. The information for the N40-45ER reach carriages is in the section REACH CARRIAGES, 4500 SRM 384.

An upright is used to raise a load vertically. Hydraulic lift cylinders are installed vertically on the uprights.

The lift cylinders raise and lower the vertical frames or weldments and the carriage or operator platform.

These uprights are two-stage or three-stage uprights.

Each type of upright is described separately in this section. The upright as-semblies include the following parts: 1. The outer upright weldment with base arms 2. The inner upright weldment 3. The intermediate upright weldment (3-stg only) 4. The lift cylinders

5. The load rollers 6. The lift chains and sheaves 7. The crosshead assembly (3-stg only) 8. The hydraulic tubing, hoses and sheaves

UPRIGHT WELDMENTS The main vertical frames of an upright assembly are called weldments. These uprights have telescopic weldments. The inner upright weldments and the carriage or operator platform move inside the outer upright weldment. The outer upright weldments fastened to the lift truck and is part of the lift truck frame. The outer upright weldment has base arms as part of the weldment. The base arms have load wheels as a support for the upright and the front of the lift truck. The outer upright weldment is also a support for the overhead guard. These uprights do not tilt forward or backward.

When the telescopic weldments and the carriage or operator platform lift a load, forces are put on the upright assembly. To decrease friction caused by these forces, load rollers and strip bearings are installed between the moving parts. The load rollers travel along the channels within the weldments.

FIGURE 1. VISTA UPRIGHTS

Hydraulic lift cylinders are installed vertically on the weldments. The Vista Two-Stage uprights have two single stage lift cylinders that raise the inner up-right weldment. The Vista Three-Stage uprights have three single-stage lift cylinders. The free-lift

cylinder raises the carriage or operator platform. The two main cylinders raise the intermediate and inner upright weldments, carriage or operator platform.

FIGURE 2. FORKS AND N40-50EA STANDARD CARRAIGE OR R30/EA/EA-FS OPERATOR PLATFORM

FIGURE 3. R30E/EA/EA-FS OPERATOR PLATFORM

CARRIAGES (N40 — 50EA ONLY) (SEE FIGURE 2) NOTE: The N40-45ER units have a carriage assembly that extends and retracts. These carriages have a separate fork carriage as part of the carriage assembly. The load backrest extension is attached to this fork carriage. See the section REACH CARRIAGES, 4500 SRM 384 for information on the reach carriages.

Each N40-50EA upright has a standard carriage. The standard carriage is a separate assembly that moves within the vertical channels of the inner upright weldment. Load rollers, attached to the carriage, travel in the channels of the inner upright weldment. The rollers decrease friction and keep the carriage aligned between the inner channels. The load sits on forks attached to the carriage. A load backrest extension is also attached to the carriage.

OPERATOR PLATFORM (R30E/EA/EA-FS ONLY) (SEE FIGURE 3) The R30E/EA/EA-FS operator platform is a separate assembly that moves within the vertical channels of the inner upright weldment. Load rollers travel in the channels of the inner upright weldment. The rollers decrease friction and keep the operator platform aligned between the inner channels. The load sits on forks attached to the bottom of the operator platform. The operator is elevated with the load. There is no load backrest extension.

The operator platform has the platform, instrument panel and controls for the operator to operate the lift truck. See the section ELECTRICAL SYSTEM ADJUSTMENTS, 2200 SRM 420 to repair and adjust the electrical controls at the operator platform.

There is also a tether line and belt for the safety of the operator.

VISTA TWO-STAGE UPRIGHT DESCRIPTION (SEE FIGURE 4) The Vista Two-Stage upright is a two-stage upright because it has two weldments. The inner upright

weldment has one load roller on each side at the bottom. The load rollers travel along the channels within the outer upright weldment. The outer upright weldment has one load roller on the inside of

FIGURE 4. VISTA TWO-STAGE UPRIGHT ASSEMBLY

each channel. The outside channels of the inner upright weldment travel on these load rollers during channel movement. The mount angle of the load rollers permit them to control the forces during movement of a load. See Figure 5. These forces are from the front, back and sides. Strip bearings also control these forces. The strip bearings are installed at the top of the outer upright weldment. Strip bearings are also installed at the bottom of the inner up-right weldment.

The strip bearings are between the channels of the weldments. The carriage or operator platform also has strip bearings. The strip bearings and the load rollers both have shims to keep the correct clearance between the weldments.

The Vista Two-Stage upright assembly has two sin-

gle-stage lift cylinders that are installed vertically at the channels of the weldments. The lift cylinders fasten to each channel at the back of the outer upright weldment. The bases of the lift cylinders fit into guides that are welded to the bottom crossmember of the outer upright weldment. Supports are also welded near the top of the channels of the outer upright weldment. Bolts fasten the shell supports to the weldment supports. See Figure 6. The rods of each lift cylinder fasten to the top crossmember of the inner upright weldment. The inner upright weldment extends from the outer upright weldment as the cylinder rods extend. The weight of the weldment, carriage or operator platform and load retract the cylinder rods.

FIGURE 5. LOAD ROLLER AND STRIP BEARING ARRANGEMENT

FIGURE 6. MAIN LIFT CYLINDER MOUNTS

Two lift chains control the movement of the carriage or operator platform. The chains fasten to supports that are welded near the top of the outer upright weldment. The chains go up and over the chain sheaves and then connect to the carriage or operator platform. The chain sheaves are installed at the inside of the channels near the top of the inner upright weldment.

The chains transfer the force from the lift cylinders to the carriage or operator platform.

OPERATION (SEE FIGURE 7) Figure 7 shows the operation of the Vista Two-Stage upright. The rods in the lift cylinders extend to move the inner upright weldment out of the outer upright weldment. Since the chain sheaves are fastened to the inner upright weldment, the force from the cylinder rods transfers to the carriage or operator platform. Movement of the carriage or operator platform that does not cause an increase in the

height of the upright assembly is free-lift. The top of the inner upright weldment and the top of the outer upright weldment are at the same height on this upright Since the inner upright weldment must move to raise the carriage or operator platform, there is no free-lift on this upright.

When the cylinder rods retract, the weight of the load, carriage or operator platform and inner upright weldment pushes the oil from the cylinders. The oil flows from the cylinders through the lowering control valves to the hydraulic tank. Each lift cylinder has a lowering control valve installed in its base. An additional lowering control valve and housing is fastened to the channel of the outer upright weldment. These valves control the lowering speed of a load if a hydraulic line breaks.

FIGURE 7. OPERATION OF THE VISTA TWO-STAGE UPRIGHT ASSEMBLY

VISTA THREE-STAGE UPRIGHT DESCRIPTION (SEE FIGURE 8) The Vista Three-Stage upright is a three-stage upright because it has three weldments. There is an outer upright weldment, and intermediate upright weldment and an inner upright weldment. The weldments are telescopic and have a load roller and strip bearing arrangement that is similar to the two-stage uprights.

The three-stage uprights have three hydraulic cylinders: the free-lift cylinder and two main-lift cylinders.

They are all single-stage lift cylinders. The free-lift cylinder fastens to the inner upright weldment and controls the movement of the carriage or operator platform. The two main cylinders fasten to the outer upright weldment and control the movement of the intermediate and inner upright weldments. The lift chains transfer the force from the free-lift cylinder to the carriage or operator platform. Two outer lift chains transfer the force form the main lift cylinders to the inner upright weldment.

Movement of the carriage or operator platform that does not cause an increase in the height of the upright assembly is free-lift. The Vista Three-Stage upright has free-lift. The free-lift cylinder raises the carriage or operator platform to the top of the

upright assembly before the intermediate and inner upright weldments move.

The free-lift cylinder fastens vertically to the bottom and next crossmember of the inner upright weldment.

See Figure 9. A crosshead fastens to the rod of the free-lift cylinder. The crosshead has sheaves for the lift chain, hydraulic hose and electrical cable (reach carriage only). The free-lift chain fastens to a crossmember at the cylinder mount. The chain then goes over the crosshead sheave and fastens to the carriage or operator platform. When the free-lift cylinder rod extends, the carriage or operator platform travels at two times the speed of the rod.

The two main lift cylinders control the movemcnt of the intermediate upright weldment. The cylinders are installed vertically at the channels of the weldments.

The cylinders fasten to the outer upright weldment at the back of each channel. The base of each cylinder fits into a mount that is welded to the outer upright weldment. Supports are welded near the top of the lift cylinder shells. Supports are also welded near the top of the channels of the outer upright weldment.

Bolts fasten the shell supports to the weldment supports. The rods of each lift cylinder fasten to the top crossmember of the intermediate upright weldment.

See Figures 6and 8.

FIGURE 8. VISTA THREE-STAGE UPRIGHT ASSEMBLY

The main-lift chains fasten to the anchors near the top rear of the outer upright weldment. The chains go over the sheaves at the top of the intermediate upright weldment. The chains then go between the channels of the intermediate and inner upright weldments and fasten to the chain anchors at the bottom of the inner upright weldment. See Figures 8 and 9.

When the main-lift cylinders raise the in-

termediate upright weldment, the chains raise the inner upright weldment, the free-lift cylinder and the carriage or operator platform.

OPERATION (SEE FIGURE 10) The Vista Three-Stage upright operates in two phases.

First, the free-lift cylinder extends and lifts the carriage or operator platform to the top of the

FIGURE 9. CHAIN AND FREE-LIFT CYLINDER MOUNT

upright assembly. When the free-lift cylinder reaches the end of its stroke, the main-lift cylinders begin to extend. The main-lift cylinders raise the in-termediate upright weldment. Since the main-lift chains go over the sheaves of the intermediate up-right weldment, the inner upright weldment also raises. The inner upright weldment travels at two times the speed of the intermediate upright weldment.

The three lift cylinders are connected hydraulically in parallel. When the LIFT function begins, the pressure of the oil increases in all the lift cylinders. The free-lift cylinder raises the weight of the carriage or operator platform and the load on the forks. The main-lift cylinders must raise the carriage or operator platform, the load on the forks,

plus the weight of the intermediate and inner upright weldments. It takes less force to extend the rod of the free-lift cylinder, so this rod and the carriage or operator platform move first.

When the LOWER function begins, the oil from the main-lift cylinders returns to the hydraulic tank. The main cylinders lower first since they have a greater load. When the main cylinder rods have fully retracted, the free-lift rod retracts. All the oil from the lift cylinders returns to the hydraulic tank through the lowering control valves. Each lift cylinder has a lowering control valve installed in its base. An additional lowering control valve and housing is fastened to the channel of the outer upright weld-ment. These valves control the lowering speed of a load if a hydraulic line breaks.

FIGURE 10. OPERATION OF VISTA THREE-STAGE UPRIGHT

INTRODUCTION GENERAL 1

This section has the procedures for the replacement of the parts of the wire guidance system. See the section WIRE GUIDANCE – DESCRIPTION, 2200 SRM 421 for the adjustment procedures necessary after replacing a part. The electrical adjustments must be done as part of the system adjustments for the system to operate correctly.

There are repair procedures for the following parts: steering mechanism, sensors at each end of the unit, and Electronic Control Module (ECM) assembly, and the gearmotor unit. There are also repair procedures for the guidance components at the instrument panel.

NOTE: Removal and repair procedures for the Master Drive Unit (MDU) are in the section MASTER DRIVE UNIT, 630 SRM 283. All mechanical parts of the steering must be in good condition and correctly adjusted for correct guidance operation. The load wheels MUST BE THE SAME SIZE, in good condition and the bearings must be lubricated and correctly adjusted.

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RTC HANDLE STEER POTENTIOMETER MULTIPLE CONDUCTOR CABLE GUIDANCE SWITCH GUIDANCE LIGHT ALARM TRACTION CIRCUIT ECM BATTERY STEERING GEARMOTOR MDU POTENTIOMETER MDU AND CHAIN SENSOR (STEER WHEEL) SENSOR (LOAD WHEEL)

FIGURE 1. WIRE GUIDANCE SYSTEM

REPAIR NOTE: See the section MASTER DRIVE UNIT, 630 SRM 283 to remove and replace the MDU.

STEERING MECHANISM Removal And Disassembly (See FIGURE 2.)

NOTE: Complete disassembly is usually not necessary.

Remove only the parts necessary to replace the defective part.

NOTE: The numbers in the “( )” of the following procedure are the item numbers in FIGURE 2.

1. Disconnect the battery so that the connector half is completely free.

2. Remove the screw (2) that fastens the steering handle to the shaft of the steering mechanism. Remove the steering handle (1).

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3. Remove the screws at the top of the instrument panel (3). Tilt the instrument panel to the open position for access to the parts.

ing installation. Use a soldering iron to remove the wires from the potentiometer.

6. If necessary, remove the nut (6), special washer (8) and thrust bearing (9) from the steering shaft (10).

7. If necessary, remove the steering shaft (10), bushing (11), index washers (12), spring (13) and nylon washers (14).

8. If necessary, remove the nut that fastens the range potentiometer (15) to the bracket. If necessary, put tags on the potentiometer wires for correct connection. Use a soldering iron to remove the wires from the potentiometer.

Assembly And Installation (See FIGURE 2.)

NOTE: The numbers in the “( )” of the following procedure are the item numbers in FIGURE 2.

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STEERING HANDLE SCREW INSTRUMENT PANEL MECHANISM BRACKET SETSCREW NUT POTENTIOMETER BRACKET SPECIAL WASHER THRUST BEARING STEERING SHAFT BUSHING INDEX WASHER SPRING NYLON WASHER RANGE POTENTIOMETER

FIGURE 2. STEERING MECHANISM

4. Remove the capscrews that fasten the steering mechanism bracket (4) to the back of the instrument panel.

5. Remove the setscrew (5) that fastens the shaft of the steering potentiometer(16) to the steering shaft (10).

Remove the capscrew and nut that fasten the potentiometer bracket (7). Remove the bracket and potentiometer. If necessary, remove the steering potentiometer (16) from the steering bracket (7). If necessary, put tags on the potentiometer wires for correct connections dur2

1. If removed, use a soldering iron to connect the wires to the range potentiometer (15). Install the potentiometer on the bracket.

2. If removed, install nylon washers (14), spring (13), index washers (12), bushing (11), steering shaft (10), thrust bearing (9), special washer (8) and nut (6).

3. If removed, use a soldering iron to connect the wires to the steering potentiometer (16). Install the potentiometer on the bracket (7).

4. Install the steering mechanism bracket (4) to the back of the instrument panel (3).

5. Connect all wires disconnected during removal. If the range potentiometer (15) was replaced or the setting was changed, adjust the range potentiometer as described in CHECKS AND ADJUSTMENTS of the section WIRE GUIDANCE – DESCRIPTION, 2200 SRM 421.

6. If the steering potentiometer (16) was replaced or the setting was changed, adjust the steering potentiometer as described in CHECKS AND ADJUSTMENTS of section WIRE GUIDANCE – DESCRIPTION, 2200 SRM 421. Tighten the setscrew (5) that fastens the potentiometer (16) to the steering shaft (10).

7. Close the instrument panel and tighten the screws. Install the steering handle (1) on the steering shaft.

Tighten the screw (2).

REPLACE GUIDANCE SWITCH, INDICATOR AND ALARM (See FIGURE 3.)

NOTE: The numbers in the “( )” of the following procedure are the item numbers in FIGURE 3.

NOTE: Removal of each part is usually not necessary.

Remove only the parts necessary to replace the defective part. The Guidance switch and indicator are located in the instrument panel. The alarm is fastened to the front (upright side) of the operator platform.

1. Disconnect the battery completely.

2. Remove the screw that fastens the steering handle to the shaft of the steering mechanism. Remove the steering handle.

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INSTRUMENT PANEL GUIDANCE SWITCH GUIDANCE INDICATOR GUIDANCE ALARM

FIGURE 3. GUIDANCE BUTTON, INDICATOR AND ALARM 3. Remove the screws at the top of the instrument panel (1). Tilt the instrument panel to the open position for access to the parts.

4. To replace the switch (2) or indicator (3), put tags on the wires for correct connection during installation. Pull the wire terminals off the switch or indicator terminals.

5. Push the switch assembly (2) or indicator assembly (3) out of the instrument panel (1). Push the replacement switch or indicator assembly into the instrument panel.

Make sure the words on the switch are not upside down.

6. To replace the alarm (4), put tags on the alarm wires for correct connection during installation. Remove the bezel nut that fastens the alarm and remove the alarm.

Install the replacement alarm and connect the wires as tagged during removal.

7. Close the instrument panel and tighten the screws. Install the steering handle on the shaft of the steering mechanism. Tighten the screw.

REPLACE MDU POTENTIOMETER (See FIGURE 4.)

NOTE: The numbers in the “( )” of the following procedure are the item numbers in FIGURE 4.

1. Set the MDU for straight travel. Disconnect the battery so that it is completely free.

2. Open the motor compartment door. Disconnect the electrical plug for the MDU potentiometer.

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3. Loosen the setscrew (6) that fastens the shaft of the potentiometer (3) to the gearmotor assembly (2). Remove the nut (5) that fastens the potentiometer to the bracket (4). Remove the potentiometer.

2. To replace the complete module, install tags on the wires at the terminal strip for correct connections during installation. Disconnect the wires from the terminal strip. Disconnect the plugs of the wiring cables.

4. Set the replacement potentiometer for mid–range. Install the replacement potentiometer on the bracket. Install the nut (5) to fasten the potentiometer, but do not tighten the nut or setscrew (6).

3. Hold the module and remove the capscrews and washers that fasten the module to the frame plate. Access to the capscrews is from the traction motor compartment.

5. Adjust the MDU potentiometer as described in CHECKS AND ADJUSTMENTS of the section WIRE GUIDANCE – DESCRIPTION, 2200 SRM 421.

Tighten the nut (5) and setscrew (6) without moving the potentiometer body or shaft to change the setting. Connect the plug.

6. Close the motor compartment doors and connect the battery.

NOTE: Keep the frame area clean to prevent voids between the power base and the frame panel. Use a piece of plastic to cover the silicon grease on the power base or remove the grease.

4. Install silicon grease on the power base of the replacement module and the frame. Install the module on the frame panel using the four capscrews and the washers.

5. Install the wires on the terminal strip as marked during removal. Connect the wiring cable plugs.

Replace The Logic Board Set (See FIGURE 5.)

NOTE: The logic board for the guidance ECM is actually a two–piece set. The set MUST be replaced as a single unit.

1.3 –3.8 mm (0.05 – 0.15 in)

NOTE: The logic board does not normally get defects. the logic board can be damaged from a malfunction of the power board. If the power board has a defect, replace the complete module. If physical damage causes a defect in the logic board, replace the logic board set as described in the following procedure.

CAUTION 12359

1. MDU 2. GEARMOTOR 3. MDU POTENTIOMETER

4. BRACKET 5. NUT 6. SETSCREW

FIGURE 4. MDU POTENTIOMETER AND ECM

The electronic components can be damaged by electrostatic discharge. Use a special floor pad to help prevent an electrostatic charge. ALWAYS remove the electrostatic charge on your body before touching electronic components. Connect a static strap to your wrist and a good earth ground. Follow the directions on the package of the component.

REPLACE THE ECM

NOTE: The numbers in the “( )” of the following procedure are the item numbers in FIGURE 5.

Replace The Complete Module (See FIGURE 4.)

1. Disconnect the battery so that it is completely free.

NOTE: Complete disassembly is usually not necessary.

Remove only the parts necessary to replace the defective part.

1. Disconnect the battery so that the connector half is completely free.

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2. Remove the nuts that fasten the cover (1) on the ECM. Install tags on all the electrical plugs (4) for correct connection during installation.

3. Disconnect the six electrical plugs (seven plugs with optional lift/lower circuit) (4). The plugs are at the edges of the two circuit boards of the set (3).

4. Remove the spacers and washers (5) that fasten the logic board set (3). Remove the logic board set.

12370

FIGURE 5. LOGIC BOARD REPLACEMENT 5. Install the replacement logic board set. Make sure the test points and LEDs are at the top. Install the washers and spacers (5) to fasten the logic board set.

6. Install the electrical plugs (4) on the edges of the logic board set as marked during removal.

4. Remove the spacers and washers that fasten the logic board set. Remove the logic board set.

5. Use a knife to carefully remove the protective coating on the terminals for the control leads of the transistor block (1) to be replaced.

7. Install the ECM cover (1) using the nuts and washers (2).

6. Put tags on the control wires and power leads for correct connection during installation. Remove the power leads from the power terminals (2).

Replace ECM Power Transistors (See FIGURE 6.)

7. Use a soldering iron and pliers that have a long nose to remove the wires from the terminals of the transistor block. Use the pliers to pull each wire off each terminal as the soldering iron melts the solder. Do not hold the soldering iron on a terminal too long. The wire can get too hot and melt the insulation.

NOTE: Make sure that the transistor block is defective before replacing the block. See Checking ECM Power Transistors in the section WIRE GUIDANCE – DESCRIPTION, 2200 SRM 421.

NOTE: The numbers in the “( )” of the following procedure are the item numbers in FIGURE 6.

1. Disconnect the battery so that it is completely free.

Open the motor compartment doors.

2. Remove the nuts that fasten the cover on the ECM. 3. Disconnect the electrical plug from each edge of the logic board set.

8. Remove the two screws and lock washers (4) that fasten the block (1) to the heat sink plate. Remove the block.

9. Put a thin coating of silicon grease on the metal plate on the bottom of the replacement transistor block.

10. Install the replacement block (1) on the heat sink.

Make sure the block is in the correct position to correctly connect the control wires. Tighten the screws (4).

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POWER TRANSISTOR BLOCK POWER TERMINALS CONTROL TEWRMINALS MOUNT SCREW AND LOCK WASHER

FIGURE 6. ECM POWER PANEL

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11. Connect the control wires to the control terminals (4) of the transistor block as marked during removal. Use solder and a soldering iron to connect the wires to the terminals. Use pliers that have a long nose to hold the terminal under the connection to help keep heat out of the transistor. Do not hold the soldering iron on a terminal too long. The terminal can get too hot and damage the transistors or melt the wire insulation. Make sure to use enough heat to make a good solder joint.

12. Connect the power leads to the power terminal (2) as marked during removal.

13. Install the logic board set, plugs and ECM cover.

Close the motor compartment doors.

REPLACE THE STEERING CONTACTOR The steering contactor is fastened to the housing of the steering motor in the motor compartment.

1. Disconnect the battery and open the motor compartment doors.

2. Put tags on the steering contactor leads for correct connection during installation.

3. Loosen the large hose clamp that fastens the contactor to the steering gearmotor. Remove the contactor.

4. Install the replacement contactor in the same position as the old contactor. Tighten the hose clamp to fasten the contactor.

5. Install the contactor leads as tagged during removal.

REPLACE THE GEARMOTOR ASSEMBLY AND STEERING CHAIN 1. Disconnect the battery and open the motor compartment doors.

2. Disconnect the electrical plug for the MDU potentiometer. Remove the nut that fastens the MDU potentiometer bracket to the frame panel.

3. Hold the gearmotor assembly and remove the capscrews, nuts and washers that fasten the gearmotor assembly to the frame panel.

4. Carefully tip the top of the assembly away from the panel to slide the MDU potentiometer bracket off the end of the capscrew. Do NOT bend the bracket. Remove the steering chain from the sprocket and remove the gearmotor assembly.

NOTE: See the section THE DC MOTOR, 620 SRM 145 or DC MOTOR MAINTENANCE, 620 SRM 294 to repair the gearmotor.

5. See FIGURE 8. to repair the gear box of the gearmotor assembly. Clean and lubricate the gears and bearings with grease (Hyster part number 347031).

6. If necessary, remove the steering chain from the MDU sprocket by pulling the chain anchor pins out of the holes in the sprocket.

7. If the steering chain was removed, clean and lubricate the chain using multi–purpose grease.

8. Make sure the MDU is aligned for straight travel. If removed, install the steering chain on the MDU sprocket. Install the pin of the chain anchor in the first hole before the axle centerline as shown in FIGURE 7.

9. Make sure the setscrew for the MDU potentiometer is aligned as shown in FIGURE 7. Install the sprocket of the replacement gearmotor assembly in the steering chain.

CAUTION If the gearmotor assembly has the MDU potentiometer installed, make sure to align the MDU potentiometer bracket on the mount capscrew during installation. Do NOT bend the bracket.

10. Hold the assembly and install the capscrews, washers and nuts that fasten the assembly to the frame panel.

Tighten the capscrews and nuts to 31 N.m (23 lbf ft).

11. If the MDU potentiometer is not installed, install the potentiometer. Make sure to install the potentiometer so that there is a clearance as shown in FIGURE 7. Adjust the MDU potentiometer as described in CHECKS AND ADJUSTMENTS of the section WIRE GUIDANCE – DESCRIPTION, 2200 SRM 421.

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GEARMOTOR ASSEMBLY FRAME PLATE MDU POTENTIOMETER POTENTIOMETER BRACKET STEERING CHAIN

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MDU SPROCKET CHAIN ANCHOR FIRST HOLE BEFORE CENTERLINE SETSCREW MUST BE AS SHOWN

FIGURE 7. GEARMOTOR AND STEERING CHAIN

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FIGURE 8. GEAR BOX ASSEMBLY 8

MOTOR ADAPTER GASKET KEY REDUCER HOUSING WORM GEAR SET BEARING CONE BEARING CUP LOAD RING OIL SEAL SHAFT COVER SNAP RING COVER RING SPACER BALL BEARING PLUG

12359

REPLACE THE SENSORS (See FIGURE 9.)

NOTE: The replacement sensors must be for the frequency of the guide wire signal at the installation. See the decal on the sensor. The standard sensor frequency is 6250 Hz. The Hyster wire driver has the frequency and wire current on a label inside the door. See the manufacturer of other wire drivers for the installation frequency.

NOTE: Each sensor must have a cable of the correct length. New sensors have either a long (load wheel) or short (steer wheel) cable. Make sure to choose the sensor with the correct cable length during replacement.

CAUTION The electronic components can be damaged by electrostatic discharge. Use a special floor pad to help prevent an electrostatic charge. ALWAYS remove the electrostatic charge on your body before touching electronic components. Connect a static strap to your wrist and a good earth ground. Follow the directions on the package of the component.

WARNING To replace the load wheel sensor, the operator platform must be raised to provide an access. The lower-

ing of the operator platform or forks can cause an injury. Use blocks and chains on the upright weldments and operator platform so that they can not move. Make sure the moving parts are attached to a part that can not move.

1. Raise the operator platform for an access to the load wheel sensor area between the load wheels. It can be necessary to remove the battery for access to the cable ties and wires from the load wheel sensor.

2. Disconnect the battery connector and remove the cover for access to the electrical compartment. Discharge capacitor C1.

CAUTION The position of motor and other power cables can change the operation of the guidance system. Do NOT change the position of power cables during the replacement of sensors.

3. Remove all the cable ties and clamps that fasten the sensor cable. Make a note of the location of each cable tie and position of the sensor cable for the installation.

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BLACK GREEN WHITE RED

BLACK GREEN WHITE RED

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1. LOAD WHEEL SENSOR 2. SENSOR BRACKET 3. SENSOR CABLE

4. TO ECM CONNECTOR 5. STEER WHEEL SENSOR 6. CAPSCREW

7. WASHER 8. NUT 9. FLOOR

10. KEY 11. PLUG “D” 12. PLUG “C”

FIGURE 9. SENSOR BOARDS 4. Remove the cover on the ECM. Remove plug connector “C” for the load wheel sensor. Remove plug connector “D” for the steer wheel sensor. Fasten a string or small gauge wire to the connector plug. The string or wire must be longer then the length of the sensor cable.

Carefully pull the cable toward the sensor. Remove the string or wire from the connector plug.

CAUTION Check the orientation of the old sensor position for the replacement installation. The replacement sensor MUST be installed so that the same side of the sensor is toward the mount surface. The replacement sensor MUST ALSO have the cable toward the same side as the old sensor. The guidance system will NOT operate correctly if the sensor is not installed correctly.

longer than the cable for the steer wheel sensor. Make sure to install the correct sensor. If necessary, loosen the capscrews and nuts at the end of the sensor bracket to align the center mark on the sensor board. Fasten the sensor so that the floor clearance is 66.5 mm (2.63 in). If possible, the center mark on the sensor must align with the centerline of the lift truck. Tighten the sensor mount capscrews and nuts to 2.0 to 2.5 N.m (18 to 22 lbf in).

7. Fasten a string or wire used during removal to the connector plug of the replacment sensor. Carefully pull the string or wire to get the sensor cable to the ECM. Remove the string or wire. Install new cable ties at the same locations of the old cable ties. Install the cable clamp near the sensor.

5. Remove the two nuts, washers and capscrews that fasten the sensor. Remove the sensor.

8. Connect the sensor connector plug to the ECM. Connect connector plug “D” (load wheel sensor) to the “D” location. See FIGURE 9.Connect connector plug “C” (steer wheel sensor). to the “C” location. Connect the battery connector.

6. Install the correct replacement sensor as shown in FIGURE 9. The cable for the load wheel sensor is

9. Adjust the ECM for the replacement sensor as described in the TEST PROCEDURES of the section

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WIRE GUIDANCE – DESCRIPTION, 2200 SRM 233. Remove the support or chain and lower the operator platform.

10. Install the ECM cover, close and fasten the electrical compartment door. Install the electrical compartment cover.

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REPRINTED

8/90

ADS PART NO. 897356

8000 SRM 422 9/88 AP Litho in U.S.A.

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8000 SRM 422

INTRODUCTION GENERAL 1

NOTE: The words “wire guidance” or “guidance” in this section describes the system of automatically steering the lift truck.

This section has the description, checks and adjustment test procedures for the parts of the wire guidance system. See the section WIRE GUIDANCE (Repair), (2200 SRM 422) to repair or replace the parts of the guidance system. During guidance operation, the system will automatically control the electric power steering.

See the section ELECTRIC POWER STEERING, (1600 SRM 418) for the steering parts of the guidance system. All mechanical parts of the steering must be in good condition and correctly adjusted for correct guidance operation. The load wheels MUST BE THE SAME SIZE, in good condition and the bearings must be lubricated and correctly adjusted.

The wire guidance system is a system to automatically steer the lift truck. The system senses a magnetic field from an electric signal carried by a guide wire buried in the floor. A wire driver generates the signal carried by the guide wire. The wire driver is part of the location installation and operates on AC power. For more information on the wire driver, see the WIRE DRIVER MANUAL, 599565.

The lift truck has the following guidance parts: (1) sensors at each end of the lift truck, (2) an Electronic Control Module (ECM), (3) a gearmotor, (4) a steering potentiometer, (5) a Master Drive Unit (MDU) potentiometer and (6) a guidance light, guidance switch and alarm at the instrument panel for operator control of the system.

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RTC HANDLE STEER POTENTIOMETER MULTIPLE CONDUCTOR CABLE GUIDANCE SWITCH GUIDANCE LIGHT ALARM TRACTION CIRCUIT ECM BATTERY STEERING GEAR MOTOR MDU POTENTIOMETER MDU AND CHAIN SENSOR (STEER WHEEL) SENSOR (LOAD WHEEL)

FIGURE 1. WIRE GUIDANCE SYSTEM There are two sensors. One sensor is at each end of the lift truck. When the lift truck is following the guide wire, each sensor is directly over the guide wire. The sensors sense the signal from the guide wire and send signals to the ECM. The ECM controls the gearmotor as indicated by the input signal from the steering potentiometer. The gearmotor turns the MDU for steering. The MDU potentiometer sends a signal to the ECM that the MDU has turned in the correct direction and the correct amount.

The automatic shut–off circuit of the ECM will decrease the lift truck speed and stop the lift truck if the guidance system cannot sense the signal from the guide wire. The shut–off circuit will also stop the lift truck if there is a malfunction of some steering component. The circuit board and the Guidance push button at the instrument panel provide operator control of the guidance system.

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A light near the Guidance push button and an alarm indicate guidance system operation. A steering potentiometer at the steering handle assembly provides the steering input signal to the ECM when the lift truck is in manual steering.

ate if the guidance system looses the signal. The system will first slow the lift truck in two stages to try to sense the signal. If the guide wire signal cannot be sensed, the system will stop the lift truck and allow the brake to engage.

Each sensor is fastened to a bracket located near the floor. The drive wheel sensor bracket is on the frame at the drive unit end of the lift truck. The bracket for the load wheel sensor is between the load wheels. The ECM is located in the motor compartment above the gearmotor. The circuit board at the instrument panel is fastened to a plate at the instrument panel. The alarm and the Guidance push button and light are also fastened at the instrument panel. There are control cables that provide the electrical connections between the cab and the electrical compartment.

The wire guidance system receives signals from the system sensors and from the MDU potentiometer. The ECM uses the input signals to keep the lift truck following the path of the wire. The ECM also operates the gearmotor for steering as described in the section ELECTRIC POWER STEERING. An input from the MDU potentiometer tells the ECM the direction and amount of steering that occurs.

OPERATION NOTE: The guidance system must have a signal from the wire driver of the correct amplitude and frequency.

The standard frequency is 6 240 to 6 260 Hz with a wire current of 76 to 80 ma. The frequency and the wire current can each be different for each installation. Make sure the frequency and wire current from the wire driver is correct for the sensors on the lift truck. See the labels on the sensors. The Hyster wire driver has the frequency and wire current on a label inside the door. See the manufacturer for other wire drivers.

The wire guidance system controls the electric power steering system to steer the lift truck along the guide wire. The operator activates the guidance system by pushing the Guidance button to the ON position. The guidance system can be activated or deactivated at any time, by pushing the button. The operator must steer the lift truck close enough to the wire for the system to sense the signal. If the lift truck is in a position so that the system senses the signal and the guidance system has been activated, the system will automatically find the guide wire.

Manual steering is possible when the guidance system is activated if the system cannot sense a signal. The alarm and flashing light will both operate during this condition. Steering will become automatic when the system is activated and the sensors can sense a signal. The alarm will stop operating and the flashing light will be continuously illuminated after the lift truck is following the guide wire. The alarm and flashing light will again oper2

In the manual steering mode, the steering input signals come from the steering potentiometer at the steering handle assembly. In the automatic steering mode (wire guidance), the steering input signals come from the sensors. The signal of the sensor from the guide wire is strongest when the sensor is directly over the wire. The signal gets weaker as the sensor moves away from the wire. During normal guidance operation, the centerline of the lift truck is over the guide wire.

How To Operate The Wire Guidance System The operation of the wire guidance system is controlled by the Guidance button. Pushing the button to the ON position, as the lift truck comes to the guide wire, energizes the guidance system to find the wire. This is the “search mode” of guidance. The Guidance light is a flashing light and the alarm makes a noise.

For the system to find the guide wire, the lift truck must be driven at a slow speed to the guide wire. The guidance system can find the guide wire at an angle of 30_ or less when traveling in the steer wheel direction. When traveling in the load wheel direction, it is necessary to align the lift truck on the guide wire. The lift truck must be aligned within approximately 44 mm (1.75 in) of the guide wire. See Figure 2. Both sensors are used when traveling in the load wheel direction. Only the steer wheel sensor is used when traveling in the steer wheel direction.

When the guidance system senses the magnetic signal from the guide wire, it automatically steers the lift truck to follow the wire. This is the “acquisition mode”. The manual steering will not operate. If the guidance system finds the guide wire, the Guidance light will not be a

flashing light , but will remain ON. The alarm stops making a noise. This is the “automatic mode”.

If the lift truck is moving too fast or is at too sharp an angle, the guidance system cannot align the lift truck on the guide wire. If this happens, the alarm continues to make noise and the light continues to be a flashing light.

The system will return to the “search mode” and it will be necessary to again manually steer the lift truck toward the guide wire.

As the guidance system first finds the guide wire, the alarm continues to make noise and the light continues to be a flashing light. The guidance system automatically steers the lift truck to align it over the guide wire (“acquisition mode”). The automatic shut–off circuit is not activated and manual steering will not operate. The automatic shut–off circuit is activated after the lift truck is aligned and the alarm stops making noise. This is the

“automatic mode”. At this time, the light will not be a flashing light, but will remain ON. If the guidance system finds the guide wire but later loses the signal from the wire, the light is a flashing light and the alarm makes noise. These conditions occur when the lift truck is approximately 32 mm (1.25 in) off the guide wire. If this happens, the system will first slow the lift truck to a maximum speed of approximately 6.4 km/h (4 mph). If the system can still not find the signal, it will again slow the lift truck to a maximum speed of approximately 3.6 km/h (2.25 mph). These conditions occur when the lift truck is approximately 38 mm (1.5 in) off the guide wire. If the system can not find the wire to return to the “automatic” mode, automatic shut–off occurs. These conditions occur when the lift truck is approximately 44 mm (1.75 in) off the guide wire. The traction circuit is deenergized and the brake is applied.

DIRECTION OF TRAVEL

DIRECTION OF TRAVEL

12379

1.

2.

3.

4.

GUIDE WIRE LOAD WHEEL GUIDANCE SENSOR STEER WHEEL

11557

FIGURE 2. OPERATION OF THE GUIDANCE SYSTEM If automatic shut–off occurs, it is necessary to reset the system. Turn the key switch to the OFF position, then energize the electrical system of the lift truck for continued operation.

When a direction change is made in guidance, the light is a flashing light and the alarm comes on for approximately 1–3 seconds. During this time the automatic shut–off function is deactivated. This permits the lift truck to make the necessary steering corrections and

then automatically steer the lift truck in the opposite direction.

NOTE: If the Guidance button is in the ON position when the key is turned to the ON position, the guidance system will automatically operate on guidance. The lift truck will operate on guidance until the Guidance button is pushed to the OFF position for manual steering or until automatic shut–off occurs. There will NOT be automatic steering unless the lift truck is on the guide wire.

3

12380

1.

2.

3.

4.

5.

6.

7.

ECM CIRCUIT BOARD LEFT DISPLAY MODE BUTTON RIGHT DISPLAY UP AND DOWN BUTTONS LED 1 STEERING POTENTIOMETER ADJUSTMENT

8.

9.

10.

11.

12.

13.

14.

15.

LED 2 MDU POTENTIOMETER ADJUST STEER SENSOR ADJUST LOAD SENSOR ADJUST SWITCHES 1 AND 2 MEDIUM SPEED ADJUST SLOW SPEED ADJUST TEST POINTS

FIGURE 3. ECM CIRCUIT BOARD

CHECKS AND ADJUSTMENTS GENERAL NOTE: Do not do any adjustments if the system operates correctly.

WARNING Do not operate a lift truck that needs adjustment or repairs. Report the need for adjustment or repairs immediately. If adjustment or repair is necessary, 4

put a “DO NOT OPERATE” tag in the operator’s area. Remove the key from the key switch.

NOTE: The checks, adjustments and test procedures in this section are for testing and adjusting the separate components. The procedures are not in a specific sequence and this sequence is NOT a troubleshooting sequence.

WARNING

TABLE 1. ECM COMPONENT FUNCTIONS

Many of the checks and adjustments are done with the battery connected. Never have any metal on your fingers, arms or neck. During some checks or adjustments, the operator must move the truck. The person doing the adjustments must make the adjustments with the system energized. Make sure the operator does not move the truck to cause an injury.

COMPONENT

To read the displays on the ECM circuit board or do the manual checks, you must have access to the ECM. For access, open the motor compartment doors and remove the ECM cover.

S1 S2

The wire guidance system uses the ECM test circuit to check for correct operation and adjustment of each part of the system. The test circuit automatically makes some checks during operation. Other checks can be done manually. These last checks are usually necessary as part of the adjustment procedures and are found in the ADJUSTMENTS and TEST PROCEDURES of this section. Switch S1, on the ECM circuit board, is used to change to the manual check mode. Push the Mode button to change between checks. The two displays, on the ECM circuit board, indicate the results of the checks.

See Figure 3 and Table 1 for the locations and functions of the parts of the circuit board. The ECM check circuit has 15 manual checks 01 – 15.

RT1 RT2 RT4 RT5 RT6 RT7

TP1 TP2 TP3 TP4 TP5 TP6 TP7 TP8 TP9 TP10 TP11 TP12 TP13 TP14 TP15

FUNCTION STEERING POTENTIOMETER MDU POTENTIOMETER STEER SENSOR LOAD SENSOR “MEDIUM SPEED” POT. “SLOW SPEED” POT. TEST SWITCH NOT USED 5 VOLTS 14 VOLTS AUTO/MANUAL INPUT STEERING INPUT SIGNAL MDU COARSE MDU MEDIUM MDU FINE 12:9 SENSOR (LOAD WHEEL) 12:3 SENSOR (LOAD WHEEL) 6:9 SENSOR (STEER WHEEL) 6:3 SENSOR (STEER WHEEL) MOTOR CURRENT NOT USED NOT USED BATTERY NEGATIVE (COMMON)

To do some of the tests correctly, the center of the sensors must be directly over the guide wire. The guidance system must have a signal from the wire driver of the correct amplitude and frequency. The standard frequency is 6240 to 6260 Hz with a wire current of 76 to 80 ma. The frequency and the wire current can each be different for each installation. Make sure the frequency and wire current from the wire driver is correct for the sensors on the lift truck. See the labels on the sensors. The Hyster wire driver has the frequency and wire current on a label inside the door. See the GUIDE WIRE INSTALLATION, 599596 and the WIRE DRIVER MANUAL, 599565 for the Hyster wire driver and guide wire installation. See the manufacturer for other wire drivers. The manual tests must be done on a straight section of the guide wire. For other checks the MDU must be set for straight travel. Do not move the steering after the MDU has been set until told to so in the procedure.

5

CHECKS

CAUTION The steering chain MUST be correctly adjusted for the guidance system to operate correctly AND to make the checks and adjustments correctly. Check and if necessary, adjust the steering chain as described at the end of the ADJUSTMENTS section.

Checking For Short–Circuits To The Frame GENERAL It is important for the correct operation of the guidance system that all system components have electrical insulation. There must be electrical insulation between the frame of the lift truck and each component. If a connector, cable, wire or component is making a connection to the frame, a malfunction can occur. The position of a motor cable can make a magnetic field that can change the sensor signal. Electrical static can also cause a malfunction. Make sure all cables are installed in the same position if they were moved for checking or replacement. Make sure all shields are correctly installed and connected. Make sure all insulation and isolators are correctly installed. Repair all short–circuits as soon as they are found. Keep the battery and battery compartment clean and painted. Keep all carbon dust and dirt removed from the inside of all the motors. Use dry compressed air.

CHECKS A. Move the lift truck away from the guide wire. Connect the negative lead from the digital voltmeter to TP15 on ECM board. Put the positive lead on terminals TP8, TP9, TP10 and TP11. The highest reading will be 1 volt.

If the reading at any of the terminals is over 1 volt, there is a wire connection to the frame, probably in the traction circuit.

B. Do the same tests with the voltmeter as in step A. Operate the hydraulic system and then the steering system.

If the reading at any of the test points is over 1 volt, there is a wire connection to the frame, probably in the hydraulic or steering circuits.

C. Move the lift truck to an area that does NOT have a guide wire. Turn the steering handle for a full right or left turn. Activate the guidance system. Accelerate the 6

lift truck without turning the steering handle. If the guidance system attempts to steer the lift truck out of the turn, there is a traction circuit connection to the frame.

The connection makes the guidance system operate as if it were on an energized guide wire. This operating condition is usually from a high resistance connection. A dirty battery or motor can cause this condition.

D. To check for wire connections to the frame, disconnect the battery and use an ohmmeter to check the circuits. Check for 50,000 ohms or more between each terminal of the part of the battery connector on the lift truck and a clean connection on the frame. Make sure there are no electrical connections to the frame of the lift truck.

Wires or terminals without insulation can cause these connections. Isolators for circuit boards that are missing, broken or not installed correctly can also cause these connections.

E. Check for voltage between each terminal of the connector on the battery and a clean metal connection on the frame of the lift truck. It is normal to measure some voltage between the battery and the frame even if the resistance checks are correct. There can be a voltage on the frame if the battery is dirty or the battery has a defect.

Clean the battery and battery compartment as necessary.

There can also be a voltage on the frame if there is carbon dust in the motors. Use dry compressed air to remove the carbon dust from all motors.

Automatic Checks The following paragraphs have a description of the automatic checks that are done by the test circuit of the ECM. See Table 2. There is also a description of the numbers on both the ECM display during normal operation. LEDs 1 and 2 will flash for any of the displays shown in Table 2.

The logic system of the ECM makes internal checks for correct operation. The checks are automatic and occur during manual or automatic steering.

NOTE: When the lift truck is aligned on an energized guide wire with the guidance system activated, the guidance system will automatically steer the lift truck.

If the lift truck moves off the guide wire by approximately 32 mm (1.25 in), the guidance system will show a display of “5d 01”. LEDs 1 and 2 will flash. The guidance system will slow the lift truck to a maximum speed of the “medium speed”. The maximum “medium speed”

for the R30E is approximately 6 km/hr (4 mph). The maximum “medium speed” for the R30EA is approximately 9 km/hr (5 mph). If the lift truck moves off the guide wire by approximately 38 mm (1.5 in) (R30E) or 32mm (1.25 in) (R30EA), the guidance system will show a display of “5d 02”. LEDs 1 and 2 will flash and the guidance system will slow the lift truck to a maximum speed of the “slow speed”. The maximum “slow speed” for the R30E and R30EA is approximately 4 km/ hr (2 mph). If the lift truck moves off the guide wire by approximately 44 mm (1.75 in), the guidance system will show a display of “A5 11”. LEDs 1 and 2 will flash and automatic shut–off occurs. The traction system is disabled and the brake is applied. All of the other “Stop Conditions” shown in Table 2 will either prevent lift truck movement in the guidance mode or stop the lift truck as just described.

TABLE 2. DISPLAY CODE DESCRIPTIONS DISPLAY 5d 01 5d 02 DISPLAY A5 00 A5 01 A5 02 A5 03 A5 04 A5 05 A5 06 A5 10 A5 11 A5 12 A5 13 A5 30 A5 31 dd dd

SLOW DOWN CONDITIONS SLOW TO “MEDIUM SPEED” SLOW TO “SLOW SPEED” STOP CONDITIONS LIFT HEIGHT OVER MAXIMUM MDU OUT OF NORMAL RANGE MDU NOT MOVING MDU MOVING WRONG STEER POT OUT OF RANGE GUIDANCE SW FAULT IN AUTO BOTH FOR. & REV. IN AUTO LOW SENSOR SIGNAL LIFT TRUCK OFF GUIDE WIRE HIGH SENSOR RATIO LOW AVERAGE SENSOR LEVEL EPROM CHECKSUM ERROR EEPROM CHECKSUM ERROR TEST MODE SELECTED

DISPLAY

NON–TRACTION CONDITIONS

dd 05 dd 06 dd 07 dd 40

GUIDANCE SW FAULT IN MANUAL F. & R. SELECTED AT SAME TIME LOGIC BOARD NOT TESTED WATCHDOG RESET OCCURED

NOTE: LEDs 1 AND 2 FLASH FOR ALL OF THE ABOVE CONDITIONS.

A display of “dd 02” shows that both forward and reverse directions have been simultaneously selected. The

lift truck will not operate. A display of “dd 05” indicates that there is a fault in the “manual” circuit of the guidance switch. The “Watchdog” check is an automatic check that checks for faults that can reset the ECM during automatic steering. The “dd 40” display indicates a “Watchdog” fault has occurred to indicate a possible problem as a guide to the service person. These faults usually occur only once. The lift truck is operational, but there could be a problem. This display can be caused by a poor connection that is a good connection most of the time.

A display of “A5 00” shows that the operator platform is above the height where travel is permitted. The traction circuit is disabled. Lowering the platform below the limit will enable the traction circuit.

A display of “A5 01” shows that the MDU potentiometer signal is out of the correct range. This fault can be caused by the following: (1) a poor connection to any of the potentiometer wires, (2) incorrect adjustment, (3) a defective potentiometer or (4) the MDU turned beyond the normal range.

A display of “A5 02” shows that there is no signal from the MDU potentiometer when there should be. This fault can be caused by a defective steering gearmotor, a mechanically jammed MDU or a defect in the MDU potentiometer or circuit.

A display of “A5 03” shows that the signal from the MDU potentiometer is the reverse of the correct signal.

This fault is caused by reversed leads to either the MDU potentiometer or steering gearmotor.

A display of “A5 04” shows that the steering potentiometer signal is out of the correct range. This fault can be caused by the following: (1) a poor connection to any of the potentiometer wires, (2) incorrect adjustment or (3) a defective potentiometer.

A display of “A5 05” shows that the signal from the Guidance switch is out of the correct range during the “acquire” or “automatic” mode. This fault can be caused by a poor connection of the switch wires.

A display of “A5 06” shows that both the forward and reverse directions have been selected when the Guidance switch is in the “automatic” mode. This fault is caused by a fault in the direction control switches, switch wiring or switch adjustments.

A display of “A5 10” shows that one of the four sensor signals is below the normal range during operation. This 7

fault can be caused by a poor connection or a defective sensor.

A display of “A5 11” shows that the lift truck is off the guide wire as previously described.

A display of “A5 12” shows that the left–to–right signal ratio of the sensors is out of the correct range. This fault can be caused by a poor connection or a defective sensor.

A display of “A5 13” shows that the average left/right signal from a sensor set has dropped below the necessary level for correct guidance operation. This fault can be caused by a defective sensor or a weak signal from the guide wire.

A display of “A5 30” shows that there is an error in the program memory of the Erasable Programable Read Only Memory (EPROM) chip. This fault can be caused by a defective EPROM or other logic device.

Manual Checks There are manual checks 01 through 15. Access the manual checks by setting switch S1 on the logic board to the “open” (down) or manual position. See Figure 3.

The lift truck electrical system must be energized to make the checks. In the manual mode the display will show “dd dd”. The two digits on the left display indicate the step number. The two digits on the right display indicate the variable value being read or adjusted. There are no decimal points, so when reading voltages, 4.1 volts will be indicated as “41” on the right display. Press the Mode switch to advance to the next check. You must advance through the steps in numerical order to get to the check you want. Traction or steering power is not enabled in some checks. Setting switch S1 to the “closed” (up) position at any time will return the system to normal operation.

CHECK 01 – OPERATOR CONTROLS

A display of “A5 31” shows that there is an error in the Electrically Erasable Programable Read Only Memory (EEPROM) chip. This fault can be caused by a defective EEPROM or other logic device. This error can also be caused by turning the power off while switch S1 is in the “open” (down) position. Then, energizing the system when switch S1 is in the “closed” (up) position. If this happens, check that the values for Check 12 and Check 15 of this section are correct. If not, adjust the values as described in ADJUSTMENTS of this SRM section.

Turn the power off for at least five seconds and then turn the power back on. If the error still exists, the logic board must be replaced.

A display of “dd dd” shows that switch S1 on the logic card is in the “open” (down) position for the check functions. Switch S1 is set to the “closed” (up) position for normal operation.

A display of “dd 02” shows that both forward and reverse signals are present at the same time. This fault is normally caused by a defective “F” or “R” switch.

A display of “dd 05” shows that the signal from the Guidance switch is out of the correct range during the “manual” mode. This fault can be caused by a poor connection of the switch wires.

A display of “dd 40” shows that Watchdog reset has occured as described earlier.

8

This check checks the operation of the operator guidance controls. Push the Mode switch on the logic board so that the left display shows “01”. The alarm will make a noise and the Guidance Indicator will flash. The right display will show “22” (2.2 volts) or less when the Guidance button is in the Manual position. The right display will show “27” to “40” (2.7 to 4.0 volts) when the Guidance button is in the Automatic position. If any of these voltages are not correct, there is a fault in the Guidance switch or associated wiring. Steering and traction operations are disabled during this check.

CHECK 02 – STEERING INPUT VOLTAGE The amplified voltage from the steering input is shown on the right display during this check. Push the Mode switch on the logic board so that the left display shows “02”. The right display will show “25” (2.5 volts) with the steering centered. The right display will show “01” to “03” (0.1 to 0.3 volts) with the steering in a full left turn. The right display will show “47” to “49” (4.7 to 4.9 volts) with the steering in a full right turn. When the lift truck is operating in guidance, voltages above 4.9 volts or below 0.1 volts will cause shut–off. Voltages below 4.7 volts or above 0.3 volts will not result in a full turn.

Steering and traction operations are disabled during this check.

CHECK 03 – MDU POTENTIOMETER COARSE AMPLIFIER The amplified voltage from the MDU potentiometer is shown on the right display during this check. Push the Mode switch on the logic board so that the left display shows “03”. The right display will show “25” (2.5 volts) with the steering set to the center. The right display will show “01” to “49” (0.1 to 4.9 volts) with the steering set from a full left to a full right turn. When the lift truck is operating in guidance, voltages above 4.9 volts or below 0.1 volts will cause shut–off. Steering and traction operations are disabled during this check.

and the last direction selected (during plugging) was steered end first (right digit “1”). The display therefore shows “11”. If the lift truck had been allowed to accelerate after plugging to a stop, the plugging signal would have been dropped. The display would show “01”.

2. The lift truck was driven load end first and coasted to a stop (no plugging). The right display will show “02”.

3. If a problem caused both forward and reverse travel to be selected at the same time for more than a second, the display would show a “03”. This display will remain until switch S1 is moved to the “closed” (up) and back to the “open” (down) position.

CHECK 04 – MDU CENTERING This check checks the MDU centering. Push the Mode switch on the logic board so that the left display shows “04”. The system will energize the steering motor to move the MDU to the position that the system considers “center”. The right display will show “25” (2.5 volts) indicating the MDU is “centered”. The MDU can be adjusted to physical center (straight travel) by adjusting RT2.

CHECK 05 – DIRECTION INPUTS This check checks each direction signal and the zero speed (plugging) signal. Push the Mode switch on the logic board so that the left display shows “05”. The right display will show one of the displays as indicated in the following table. The left digit of the right display will show the presence or absence of the plugging signal.

The right digit of the right display shows the direction status. The traction and steering systems are both operational during this check. An “X” indicates that it does not matter what digit is indicated. These digits can be “0” to “3”.

00 INITIAL DISPLAY BEFORE ANY DIRECTION IS SELECTED X1 LAST DIRECTION SELECTED WAS STEERED END FIRST X2 LAST DIRECTION SELECTED WAS LOAD END FIRST X3 LAST DIRECTION SELECTED WAS BOTH DIRECTIONS (FAULT) 0X NO PLUGGING SIGNAL 1X PLUGGING SIGNAL WAS PRESENT EXAMPLES: 1. The lift truck was driven load end first and plugged to a stop. The plugging signal was present (left digit “1”)

11557

FIGURE 4. DIRECTION ORIENTATION CHECKS 06 THROUGH 09 – SENSOR LEVELS Checks 06 through 09 display the values from the sensor input voltages. Check that check 06 displays the value for the left–hand sensor of the steered end sensor pair (6:9). See Figure 4. Check that check 07 displays the value for the right–hand sensor of the steered end sensor pair (6:3). Check that check 08 displays the value for the left–hand sensor of the load end sensor pair (12:9).

Check that check 09 displays the value for the right– hand sensor of the load end sensor pair (12:3). Steering and traction operations are disabled during these checks.

CHECK 10 – STEERED END SENSOR BALANCE This check checks the balance between the sensor pair of the steered end sensor. The lift truck MUST be in the position so that the SENSOR at the steered end is centered over the energized guide wire. Set switch S1 to the 9

“closed” (up) position to allow manual lift truck operation. After the lift truck is centered, set switch S1 to the “open” (down) position and push the Mode switch on the logic board so that the left display shows “10”. If the right–hand display does not show “00”, the sensor pair is not balanced. The balance can be set by adjusting RT4 for a display of “00”. Steering and traction operations are disabled during these checks.

CHECK 11 – LOAD END SENSOR BALANCE This check checks the balance between the sensor pair of the load end sensor. The lift truck MUST be in the position so that the SENSOR at the load end is centered over the energized guide wire. Set switch S1 to the “closed” (up) position to allow manual lift truck operation. After the lift truck is centered, set switch S1 to the “open” (down) position and push the Mode switch on the logic board so that the left display shows “11”. If the right–hand display does not show “00”, the sensor pair is not balanced. The balance can be set by adjusting RT5 for a display of “00”. Steering and traction operations are disabled during these checks.

CHECK 12 – LOAD END FIRST RATIO This check checks the ratio setting which determines the amount of steering correction for a given position error.

The position error is the amount that the load end sensor is misaligned (off center) from the guide wire. The nominal ratio setting is 10. The setting can be changed by pushing the UP or DOWN buttons on the logic board.

The MODE button MUST be pushed to enter a new setting. If the key switch is set to OFF or switch S1 is set to the “closed” (up) position before pushing the MODE button, the new setting will NOT be entered. Steering and traction operations are disabled during these checks.

CHECK 13 – MEDIUM TRAVEL SPEED This check puts the lift truck in the medium travel speed mode to set the medium travel speed. Adjust RT6 to set the speed as described in ADJUSTMENTS of this section. The traction and steering systems are both operational during this check.

CHECK 14 – SLOW TRAVEL SPEED This check puts the lift truck in the slow travel speed mode to set the slow travel speed. Adjust RT7 to set the speed as described in ADJUSTMENTS of this section.

10

The traction and steering systems are both operational during this check.

CHECK 15 – TRUCK CONFIGURATION This check checks the setting of the truck configuration for the parameters for the high lift speed restriction. This setting can be different for different lift truck models and different upright lift heights or operating conditions. The setting can be changed by pushing the UP or DOWN buttons on the logic board. The MODE button MUST be pushed to enter a new setting. If the key switch is set to OFF or switch S1 is set to the “closed” (up) position before pushing the MODE button, the new setting will NOT be entered. Set the configuration value to “00” for the R30E. Set the configuration value to “01” for the R30EA. Steering and traction operations are disabled during these checks.

Set switch S1 to the “closed” (up) position to return the system to normal operation. On R30E units, check that the traction system is disabled at lift heights above 3810 mm (150 in). The steering can be set at any position. The traction system must still not operate. On R30EA units, check that the traction system is disabled at lift heights above 3810 mm (150 in) if the steering is at an angle greater than seven degrees. If the steering is within seven degrees, the traction system must operate at all lift heights. Fully lower the operator platform and check that the R30EA operates at a slower speed when traveling load–end–first on guidance. The R30EA units must operate at full speed in the opposite direction on guidance or when in the manual steering mode.

CHECK THE OPERATION OF THE SHUT–OFF CIRCUIT A. Move the lift truck to a section of guide wire that has a straight section.

B. Energize the guidance system of the lift truck. Make sure the guide wire is correctly energized.

C. Align the centerline of the lift truck on the guide wire.

Operate the lift truck along the straight section of the guide wire in the steer wheel direction. Stop the lift truck and disconnect wire 5P2 from terminal 2 of the power terminal strip on the ECM. Install tape on the wire to prevent a short–circuit.

D. Operate the lift truck at a slow speed on guidance in the steer wheel direction.

E. Check that the lift truck slowly moves off the guide wire. If the lift truck moves off the guide wire by ap-

proximately 32 mm (1.25 in), the guidance system will show a display of “5d 01”. LEDs 1 and 2 will flash and the guidance system will slow the lift truck to a maximum speed of approximately 6 km/h (4 mph). If the lift truck moves off the guide wire by approximately 38 mm (1.5 in), the guidance system will show a display of “5d 02”. LEDs 1 and 2 will flash and the guidance system will slow the lift truck to a maximum speed of approximately 4 km/h (2 mph). If the lift truck moves off the guide wire by approximately 44 mm (1.75 in), the guidance system will show a display of “A5 11”. LEDs 1 and 2 will flash and automatic shut–off occurs. The traction system is disabled and the brake is applied.

CHECK THE STEERING AT MAST HEIGHTS A. Raise the operator platform to 3810 mm (150 in) or more.

B. Set the steering for a right or left turn of more than 7°.

C. Check that the traction system is disabled.

D. Set the steering for less than a 7° turn (straight travel).

E. Check that the traction system will operate.

CHECK THE ECM POWER TRANSISTORS (See FIGURE 5.)

A. Disconnect the battery. Open the motor compartment door and remove the cover on the ECM. B. Remove the electrical plug at the right side of the logic card.

C. Use a Fluke model 8060A multimeter. Set the multimeter to do the diode test as described in the Fluke instruction manual.

NOTE: The specifications values shown in FIGURE 5. were taken using a Fluke Model 8060A multimeter.

Other meters and other transistor manufacturers will give different readings because of internal differences in the meters and transistors. When using other meters, compare the resistance values of the transistors being tested to the resistance values of a new transistor of the same manufacturer. Allow a + or – 10% variation for correct readings. The readings must be within the values shown in the table.

D. Connect the meter to each of the locations shown in Table 3 and check for the resistance values listed. If any of the 12 readings for EACH transistor block (M1 AND M2) are not within the values shown, replace the transistor block that has the incorrect reading. See Repair of this section to replace a power transistor block.

CHECKING THE STEERING CONTACTOR The steering contactor is fastened to the housing of the steering motor in the motor compartment.

NOTE: Make sure Fuse 4 is good before checking the contactor. Fuse 4 is an in–line fuse holder near the ECM. A. Disconnect the battery and open the motor compartment doors.

B. Check that wires 10 and 13 are connected to the control terminals of the contactor. Check that cables 3P2 and 4P2 are connected to the power terminals. Check that all connections and wires are in good condition.

C. If all connections are good, remove wire 10 or 13 from the control terminals. Use an ohmmeter to check for continuity between the control terminals. If there is continuity, the contactor coil is good. If not, replace the contactor. See REPAIR of this section.

11

TERMINAL CONNECTIONS

+

–

B1!

B1!

C1 C1 C2/E1 C2/E1

C2/E1 C1 B1!

C2/E1 C1 B1!

B2@ B2@ C2/E1 C2/E1 E2 E2

E2 C2/E1 B2@ E2 C2/E1 B2@

RESISTANCE VALUES IN OHMS

12370

80 – 400 450 – 600 OPEN OPEN 350 – 550 80 – 400 80 – 400 450 – 600 OPEN OPEN 350 – 550 80 – 400

! Plug pin socket 4 (M1), pin socket 7 (M2) @ Plug pin socket 6 (M1), pin socket 9 (M2)

FIGURE 5. TRANSISTOR RESISTANCE

ADJUSTMENTS

and if necessary, adjust the steering chain as described at the end of the ADJUSTMENTS section.

General

CAUTION The steering chain MUST be correctly adjusted for the guidance system to operate correctly AND to make the checks and adjustments correctly. Check 12

NOTE: Do not do any adjustments if the system operates correctly.

NOTE: Make sure the battery has a corrected specific gravity of at least 1.250.

WARNING Do not operate a lift truck that needs adjustment or repairs. Report the need for adjustment or repairs immediately. If adjustment or repair is necessary, put a “DO NOT OPERATE” tag in the operator’s area. Remove the key from the key switch.

NOTE: The adjustment procedures in this section are for adjusting the separate components. The procedures are not in a specific sequence and this sequence is NOT a troubleshooting sequence.

WARNING

and rotating the body until the correct resistance value is obtained. Tighten the nut without moving the potentiometer.

B. This adjustment is NOT necessary if the system has been previously adjusted correctly. Set the steering range potentiometer to the maximum clockwise position. This potentiometer is near the return–to–center potentiometer.

C. Make sure the battery is connected and move the key to the ON position. Measure the voltage between terminal 1 (wire 19) (positive) and terminal 3 (wire 21) (negative) of the return–to–center potentiometer. Record the voltage value.

Many of the adjustments are done with the battery connected. Never have any metal on your fingers, arms or neck. During some adjustments, the operator must move the truck. The person doing the adjustments must make the adjustments with the system energized. Make sure the operator does not move the truck to cause an injury.

Some of the following adjustments are done using the ECM check circuit. For access to the ECM circuit board, open the motor compartment doors and remove the cover from the ECM.

Adjusting The Return–To–Center Steer And Range Potentiometers (See FIGURE 6.)

The return–to–center steer and range potentiometers are at the steering mechanism in the instrument panel. Remove the screws at the top of the instrument panel and tilt the panel to the open position for access to the potentiometers.

NOTE: This adjustment is NOT necessary if the system has been previously adjusted correctly. Steps A and B are for initial adjustment after removing or replacing the steer or range potentiometer only. If the system has been adjusted, go to step C. A. An internal spring returns the steering handle to the straight travel position. The return–to–center potentiometer must be at the mid–range position when the steering handle is in the straight travel position. The potentiometer is at the mid–range position when the resistance readings between terminals 1–2 (wires 19–20) and terminals 2–3 (wires 20–21) are equal within 100 ohms.

Adjust the potentiometer by loosening the retaining nut

12361

1.

2.

3.

4.

5.

6.

RTC HANDLE INSTRUMENT PANEL STEER POTENTIOMETER RETAINING NUT RANGE (SPA) POTENTIOMETER COWEL CAPSCREWS

FIGURE 6. RETURN–TO–CENTER STEERING ASSEMBLY D. Move the steering handle for a full left turn. Measure the voltage between wire 20 (positive) and wire 21 (negative) at the potentiometer. Record the voltage value.

E. Move the steering handle for a full right turn. Measure the voltage between wire 20 (positive) and wire 21 (negative) at the potentiometer. Record the voltage value. Subtract the value of step (d) from the value measured in this step. Record the value. If the value is 3.36 + or – 0.1, go to step H. If not, go to step F. 13

F. Divide 3.36 by the value of step E. Record the value.

Multiply this value by the value of step C. Record the result.

E. Check the the right–hand display changes to between “47” and “49” with the steering handle moved for a full left turn.

G. Measure the voltage at the return–to–center potentiometer wire 19 (positive) and wire 21 (negative). This value must be the same as the resultant value of step F. If the value is not correct, adjust the steering range potentiometer for the resultant value of step F within 0.05 volts.

F. If any of the readings are not correct, check the return– to–center potentiometer for normal rotation.

H. Measure the voltage between terminal 2 (wire 20) (positive) and terminal 3 (wire 21) (negative). This voltage must be 2.5 + or – 0.05 volts. If the voltage is not correct, adjust the voltage by loosening the retaining nut and moving the return–to–center potentiometer body for the correct voltage. Tighten the nut without moving the potentiometer.

I. Do steps C through H again to make sure the adjustments are correct.

CAUTION Do not move the steering handle until the Steering Input Balance adjustment is complete.

Adjusting The Balance Of The Steering Input Signal (See FIGURE 3.)

The balance potentiometer RT1 is on the ECM circuit board shown in FIGURE 3.

CAUTION Make sure the steering handle is set for straight travel as described in step I of the Return–To–Center steering adjustment procedure.

A. Set switch S1 on the ECM circuit board to the “open” (down) position. With the key switch ON, the displays will show “dd dd”.

B. Push the Mode switch on the ECM for a left display of “02”.

Setting The MDU For Straight Travel (See FIGURE 3. And FIGURE 7.)

The MDU potentiometer is on the speed reducer of the steering gearmotor. The potentiometer for adjusting straight travel (RT2) is on the ECM. Before starting this procedure, find a section of floor that is smooth and level for approximately 30 m (100 feet). Install a pointer at the center of the front (MDU end) of the lift truck.

CAUTION Make sure the Return–To–Center steer and range potentiometers are adjusted according to the procedure. Make sure the Steering Input Signal is balanced according to the procedure.

Do NOT move the steering handle.

A. Push the Mode switch on the ECM for a left display of “04”. The system will energize the steering motor to move the MDU to the position that the system considers “center”. The right display will show “25” (2.5 volts) indicating the MDU is “centered”. To check and adjust the MDU to the physical center (straight travel), do step B. B. Do not move the steering handle, but have the operator drive the lift truck forward (MDU end first). Adjust potentiometer RT2 for straight travel as described in sub steps 1 through x. Clockwise adjustment of RT2 makes the lift truck turn to the right. Counterclockwise adjustment makes the lift truck turn to the left. Potentiometer RT2 is correctly adjusted when the lift truck will travel in a straight line within 152 mm (6 in) in 9 metres (30 feet). To check that the lift truck is moving in a straight line, do the following procedure:

C. Adjust RT1 for a right–hand display of “25”.

1. Make a mark on the floor under the point of the pointer.

D. Check that the right–hand display changes to between “01” and “03” with the steering handle moved for a full right turn.

2. Have the operator drive the lift truck forward for 5 metres (15 feet) as in step C. Make a mark on the floor under the point of the pointer.

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3. Have the operator drive the lift truck forward for another 5 metres (15 feet). Make another mark on the floor under the point of the pointer.

4. Draw a straight line between the first and last marks.

The center mark must be within 76 mm (3 in) of the line. If the center mark is within this specification, RT2 is correctly adjusted. If the mark is NOT within the specification, adjust RT2 as described in this procedure until the mark is within the specifications.

C. After the MDU is set for straight travel (step B), adjust the MDU potentiometer for mid–range. Push the Mode switch for a left–hand display of “03”. The potentiometer is at the mid–range position when the right– hand display shows “25” (2.5 volts). If necessary, adjust the potentiometer by loosening the retaining nut and moving the potentiometer body for the correct display.

Tighten the retaining nut without moving the potentiometer body.

D. Check for the correct range by moving the steering handle from a full left turn to a full right turn. The right– hand display will change between “01” and “49”. The MDU will move 85 to 95 degrees in each direction from the center position.

E. Set switch S1 on the circuit board to the “closed” (up) position for normal operation. Make sure the Guidance button is in the OFF (manual) position. Drive the lift truck in the MDU direction and check that it is traveling in a straight line as described in step B. If the lift truck is NOT traveling in a straight line, adjust RT1 slightly until it does. Do NOT adjust RT2.

Adjusting The Travel Speeds (See FIGURE 3., FIGURE 8. And FIGURE 9.)

MEDIUM SPEED The medium travel speed adjustment, RT6, is on the ECM circuit board. The “medium speed” for the R30E units is adjusted to 6.1 + or – 0.5 km/hr (3.8 + or – 0.3 mph). The “medium speed” for the R30EA units is adjusted to 8.4 + or – 0.5 km/hr (5.2 + or – 0.3 mph).

A. Make sure the battery has a corrected specific gravity of at least 1.250. Make sure that the lift truck has been operated at full speed for approximately 10 minutes before checking the speed.

B. Find a section of floor that is smooth and level for approximately 30 m (100 feet).

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1.3 – 1.8 mm (0.05 – 0.15 in)

C. Set switch S1 on the ECM circuit board to the “open” (down) position. Push the Mode button for a left–hand display of “13”. This will set the control card to adjust the maximum travel speed for the lift truck.

D. Move the lift truck to the beginning of the approximate 30 m (100 foot) distance. Put lines on the floor for 17 m (56 foot) and 12 m (38 foot) distances in the center of the 30 m (100 foot) distance. See Figure 8. The area at each end is for acceleration and a distance to stop the lift truck.

12359

1.

2.

3.

4.

MDU GEAR MOTOR MDU POTENTIOMETER BRACKET

5.

6.

7.

8.

NUT SETSCREW ECM RT2

FIGURE 7. MDU POTENTIOMETER ADJUSTMENT

E. Have other personnel at the start line and the 17 m (56 foot) line (R30E) or the 12 m (38 foot) line R30EA to check the times. These “finish lines” are shown in Figure 8 (item 7 R30EA) or (item 9 R30E). Operate the lift truck at full speed and check the total time it takes for the lift truck to travel the distance (6 or 8, Fig. 8). The lift truck must travel at full speed for the total time of the distance.

15

1. ECM CIRCUIT BOARD 2. RT6 MEDIUM SPEED ADJUSTMENT 3. RT7 SLOW SPEED ADJUSTMENT

12380

FIGURE 8. TRAVEL SPEED ADJUSTMENT F. If the time is less than 10 seconds for the R30E or less than 5 seconds for the R30EA, the “medium” travel potentiometer RT6 is set for a speed faster than the specified speed. The potentiometer must be adjusted ccw. If the time is more than 10 seconds (R30E) or 5 seconds (R30EA), the potentiometer must be adjusted clockwise for a faster travel speed. Adjust the potentiometer in small amounts and repeat steps D and E until the speed is correct.

SLOW SPEED The slow travel speed adjustment, RT7, is on the ECM. The “slow speed” for all units is adjusted to 3.8 + or – 0.5 km/hr (2.25 + or – 0.3 mph).

A. Make sure the battery has a corrected specific gravity of at least 1.250. Make sure that the lift truck has been operated at full speed for approximately 10 minutes before checking the speed.

B. Find a section of floor that is smooth and level for approximately 30 m (100 feet).

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C. Set switch S1 on the ECM circuit board to the “open” (down) position. Push the Mode button for a left–hand display of “14”. This will set the maximum travel speed for the lift truck. The correct maximum travel speed for the “slow speed” is D. Move the lift truck to the beginning of the approximate 30 m (100 foot) distance. Put lines on the floor for a foot) distance in the center of the 30 m (100 foot) distance. See Figure 8. The area at each end is for acceleration and a distance to stop the lift truck.

E. Have other personnel at the start line and the 9 m (29 foot) line to check the times. Operate the lift truck at full speed and check the total time it takes for the lift truck to travel the 10 m (33 foot) distance (4, Fig. 8). The lift truck must travel at full speed for the total time of the 10 m (33 foot) distance.

F. If the time is less than 10 seconds, the “slow” travel potentiometer RT7 is set for a speed faster than the specified speed. The potentiometer must be adjusted ccw. If the time is more than 10 seconds the potentiometer must be adjusted clockwise for a faster travel speed.

Adjust the potentiometer in small amounts and repeat steps C and D until the speed is correct.

3

7

5

9

1

X

2

10 4 6 8

1.

2.

3.

4.

BEGIN ACCELERATION ACCELERATION AREA START TIMING LINE TIMED DISTANCE RT7

5.

6.

7.

8.

10m (33 ft) LINE TIMED DISTANCE RT6 (R30EA) 12 m (38 ft) LINE (R30EA) TIMED DISTANCE RT6 (R30E)

9. 17 m (56 ft) LINE (R30E) 10. STOPPING AREA

FIGURE 9. CHECKING LIFT TRUCK TRAVEL SPEEDS

Setting Truck Configuration

Set switch S1 on the ECM circuit board to the “open” (down) position. Push the Mode button for a left–hand display of “15”. Push the Up or Down buttons to the right of the display to change the right–hand display.

The right–hand display must read “00” for R30E units and “01” for R30EA units. Push the Mode button to enter the setting. If the Mode button is not pushed, the new setting will not be entered. Set switch S1 to the “closed” (up) position to return the lift truck to normal operation.

Adjusting Sensors To Lift Truck Centerline

CAUTION Make sure that all of the previous adjustment procedures have been completed correctly. The following adjustments will NOT be correct if the previous adjustments are not correct. THE FOLLOWING ADJUSTMENTS MUST BE DONE IN THE SEQUENCE LISTED.

CAUTION Use a section of guide wire at least 30.5 m (100 ft) long. This section must be straight within 3.2 mm (0.125 in) in 3.05 m (10 ft). The guide wire frequency and current must match the sensors. The standard frequency and current is 6.25 KHz at 78 ma.

A. Measure the lift truck width to locate the centerline at each sensor location. Install vertical pointers at the centerline. Nylon tie wraps work well for the pointers.

The points of the pointers must just clear the floor and be visible during travel.

B. If necessary, adjust each sensor so that the center of the sensor is on the centerline and has a floor clearance of 65.09 to 68.26 mm (2.5625 to 2.6875 in).

C. Move the lift truck so that both pointers are over the guide wire. The steered end sensor must be within 2.5 mm (0.1 in) and the load end sensor must be within 76 mm (3 in).

D. Set switch S1 on the ECM circuit board to the “open” (down) position. Push the Mode button for a left–hand display of “10”. Adjust RT4 on the circuit board for a right–hand display of “00”.

E. If necessary, move the lift truck so that the load end pointer is over the guide wire. The load end sensor must be within 2.5 mm (0.1 in) and the steered end sensor must be within 76 mm (3 in).

F. Push the Mode button for a left–hand display of “11”.

Adjust RT5 on the circuit board for a right–hand display of “00”.

G. Push the Mode button for a left–hand display of “12”.

Use the Up or Down buttons to set the right–hand display to “10”. Push the mode button to enter the new setting. Set switch S1 to the “closed” (up) position to return the lift truck to normal operation.

H. Push the Guidance button on the instrument panel to the ON position for guidance operation. Operate the lift 17

truck in the direction of the MDU. Check that the steered end pointer stays within 13 mm (0.5 in) of the guide wire. Check that the load end pointer is approximately the same distance from the guide wire and on the same side as the steered end pointer. If the load end sensor is not following in the correct position, the steered end pointer AND sensor must be moved. Move the steered end pointer and sensor so that they are the on the same side and are the same distance from the guide wire.

Make sure to maintain the correct floor clearance (step B) and keep the centers of the sensor and pointer on the same centerline. Repeat this step until the pointers track correctly.

NOTE: If the pointers are basically 5 mm (0.2 in) or more to one side of the guide wire, recheck the MDU potentiometer RT2 adjustment. Also recheck the sensor balance adjustment (step D).

I. Operate the lift truck in the direction of the load wheels. Check that the load end pointer stays within 13 mm (0.5 in) of the guide wire. If the pointers are basically 5 mm (0.2 in) or more to one side of the guide wire, the steered end pointer AND sensor must be moved.

Measure the distance that the load end pointer is off the guide wire. Move the steered end pointer and sensor to a position the same distance from the guide wire on the opposite side.

EXAMPLE: If the load end pointer is 13 mm (0.5 in) to the right of the guide wire, move the steered end sensor and pointer 13 mm (0.5 in) to the left of the guide wire.

J. Do steps H and I until both pointers stay on the guide wire without any adjustment.

Adjusting The Steering Chain (See FIGURE 10.)

A. Disconnect the battery and open the motor compartment doors.

B. Operate the steering to find the point where the steering chain has the least clearance. Move the steering wheel or handle to turn the MDU to the full clockwise

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(cw) position. Slowly turn the MDU in the counterclockwise position and watch the steering chain. The point of least clearance is the point where the steering chain is straight or nearly straight between the sprockets.

C. Install a thin piece of rigid material on the chain between the sprockets. The material must have a straight edge. Make sure the chain is tight on the opposite side of the sprockets. Measure the clearance between the bottom of the straight edge of the rigid material and the chain. See Figure 9. The middle of the chain must have a clearance of 1.3 to 3.3 mm (0.05 to 0.13 in).

1.3 TO 3.3 mm (0.05 TO 0.13 in)

3072

1. REDUCER SPROCKET 4. ADJUSTING NUT 2. STEERING COLUMN 5. ADJUSTING BOLT 3. MDU SPROCKET 6. RIGID MATERIAL

FIGURE 10. ADJUSTING THE STEERING CHAIN D. Tighten the adjustment nut at the MDU sprocket for a maximum clearance of 1.3 to 3.3 mm (0.05 to 0.13 in) between the chain and straight edge. Do NOT tighten the adjusting nut for a clearance of less than 1.3 mm (0.05 in).

E. Close and fasten the motor compartment doors.

GENERAL INFORMATION

WIRE GUIDANCE

DESCRIPTION ORDERMASTERt

R30E, R30EA Part No. 897355 2200 SRM 421 First Cover Date: 9/88

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